Binders and materials made therewith

ABSTRACT

Binders to produce or promote cohesion in non-assembled or loosely assembled matter.

This application is a continuation of U.S. application Ser. No. 15/797,349 (now U.S. Pat. No. 10,759,695), filed Oct. 30, 2017, which is a continuation of U.S. application Ser. No. 12/524,539 (now U.S. Pat. No. 9,828,287), filed Jul. 24, 2009, which is a U.S. national counterpart application of international application Serial No. PCT/US2007/001892, filed Jan. 25, 2007.

BACKGROUND

Binders are useful in fabricating materials from non-assembled or loosely-assembled matter. For example, binders enable two or more surfaces to become united. Binders may be broadly classified into two main groups: organic and inorganic, with the organic materials being subdivided into those of animal, vegetable, and synthetic origin. Another way of classifying binders is based upon the chemical nature of these compounds: (1) protein or protein derivatives; (2) starch, cellulose, or gums and their derivatives; (3) thermoplastic synthetic resins; (4) thermosetting synthetic resins; (5) natural resins and bitumens; (6) natural and synthetic rubbers; and (7) inorganic binders. Binders also may be classified according to the purpose for which they are used: (1) bonding rigid surfaces, such as rigid plastics, and metals; and (2) bonding flexible surfaces, such as flexible plastics, and thin metallic sheets.

Thermoplastic binders comprise a variety of polymerized materials such as polyvinyl acetate, polyvinyl butyral, polyvinyl alcohol, and other polyvinyl resins; polystyrene resins; acrylic and methacrylic acid ester resins; cyanoacrylates; and various other synthetic resins such as polyisobutylene polyamides, courmarone-idene products, and silicones. Such thermoplastic binders may have permanent solubility and fusibility so that they creep under stress and soften when heated. They are used for manufacturing various products, for example, tapes.

Thermosetting binders comprise a variety of phenol-aldehyde, urea-aldehyde, melamine-aldehyde, and other condensation-polymerization materials like the furane and polyurethane resins. Thermosetting binders may be characterized by being transformed into insoluble and infusible materials by means of either heat or catalytic action. Binder compositions containing phenol-, resorcinol-, urea-, melamine-formaldehyde, phenol-furfuraldehyde, and the like are used for the bonding of textiles, plastics, rubbers, and many other materials.

As indicated above, binders are useful in fabricating materials from non-assembled or loosely-assembled matter. Accordingly, compositions capable of functioning as a binder are desirable.

SUMMARY

Cured or uncured binders in accordance with an illustrative embodiment of the present invention may comprise one or more of the following features or combinations thereof. In addition, materials in accordance with the present invention may comprise one or more of the following features or combinations thereof:

Initially it should be appreciated that the binders of the present invention may be utilized in a variety of fabrication applications to produce or promote cohesion in a collection of non-assembled or loosely-assembled matter. A collection includes two or more components. The binders produce or promote cohesion in at least two of the components of the collection. For example, subject binders are capable of holding a collection of matter together such that the matter adheres in a manner to resist separation. The binders described herein can be utilized in the fabrication of any material.

One potential feature of the present binders is that they are formaldehyde free. Accordingly, the materials the binders are disposed upon may also be formaldehyde free (e.g., fiberglass). In addition, the present binders may have a reduced trimethylamine content as compared to other known binders.

With respect to the present binder's chemical constituents, they may include ester and/or polyester compounds. The binders may include ester and/or polyester compounds in combination with a vegetable oil, such as soybean oil. Furthermore, the binders may include ester and/or polyester compounds in combination with sodium salts of organic acids. The binders may include sodium salts of inorganic acids. The binders may also include potassium salts of organic acids. Moreover, the binders may include potassium salts of inorganic acids. The described binders may include ester and/or polyester compounds in combination with a clay additive, such as montmorillonite.

Furthermore, the binders of the present invention may include a product of a Maillard reaction. For example, see FIG. 2. As shown in FIG. 2, Maillard reactions produce melanoidins, i.e., high molecular weight, furan ring- and nitrogen-containing polymers that vary in structure depending on the reactants and conditions of their preparation. Melanoidins display a C:N ratio, degree of unsaturation, and chemical aromaticity that increase with temperature and time of heating. (See, Ames, J. M. in “The Maillard Browning Reaction—an update,” Chemistry and Industry (Great Britain), 1988, 7, 558-561, the disclosure of which is hereby incorporated herein by reference). Accordingly, the subject binders may be made via a Maillard reaction and thus contain melanoidins. It should be appreciated that the subject binders may contain melanoidins, or other Maillard reaction products, which products are generated by a separate process and then simply added to the composition that makes up the binder. The melanoidins in the binder may be water-insoluble. Moreover, the binders may be thermoset binders.

The Maillard reactants to produce a melanoidin may include an amine reactant reacted with a reducing-sugar carbohydrate reactant. For example, an ammonium salt of a monomeric polycarboxylic acid may be reacted with (i) a monosaccharide in its aldose or ketose form or (ii) a polysaccharide or (iii) with combinations thereof. In another variation, an ammonium salt of a polymeric polycarboxylic acid may be contacted with (i) a monosaccharide in its aldose or ketose form or (ii) a polysaccharide, or (iii) with combinations thereof. In yet another variation, an amino acid may be contacted with (i) a monosaccharide in its aldose or ketose form, or (ii) with a polysaccharide or (iii) with combinations thereof. Furthermore, a peptide may be contacted with (i) a monosaccharide in its aldose or ketose form or (ii) with a polysaccharide or (iii) with combinations thereof. Moreover, a protein may be contacted with (i) a monosaccharide in its aldose or ketose form or (ii) with a polysaccharide or (iii) with combinations thereof.

It should also be appreciated that the binders of the present invention may include melanoidins produced in non-sugar variants of Maillard reactions. In these reactions an amine reactant is contacted with a non-carbohydrate carbonyl reactant. In one illustrative variation, an ammonium salt of a monomeric polycarboxylic acid is contacted with a non-carbohydrate carbonyl reactant such as pyruvaldehyde, acetaldehyde, crotonaldehyde, 2-furaldehyde, quinone, ascorbic acid, or the like, or with combinations thereof. In another variation, an ammonium salt of a polymeric polycarboxylic acid may be contacted with a non-carbohydrate carbonyl reactant such as pyruvaldehyde, acetaldehyde, crotonaldehyde, 2-furaldehyde, quinone, ascorbic acid, or the like, or with combinations thereof. In yet another illustrative variation, an amino acid may be contacted with a non-carbohydrate carbonyl reactant such as pyruvaldehyde, acetaldehyde, crotonaldehyde, 2-furaldehyde, quinone, ascorbic acid, or the like, or with combinations thereof. In another illustrative variation, a peptide may be contacted with a non-carbohydrate carbonyl reactant such as pyruvaldehyde, acetaldehyde, crotonaldehyde, 2-furaldehyde, quinone, ascorbic acid, or the like, or with combinations thereof. In still another illustrative variation, a protein may be contacted with a non-carbohydrate carbonyl reactant such as pyruvaldehyde, acetaldehyde, crotonaldehyde, 2-furaldehyde, quinone, ascorbic acid, and the like, or with combinations thereof.

The melanoidins discussed herein may be generated from melanoidin reactant compounds (e.g., Maillard reactants). These reactant compounds are disposed in an aqueous solution at an alkaline pH and therefore are not corrosive. That is, the alkaline solution prevents or inhibits the eating or wearing away of a substance, such as metal, caused by chemical decomposition brought about by, for example, an acid. The reactant compounds may include a reducing-sugar carbohydrate reactant and an amine reactant. In addition, the reactant compounds may include a non-carbohydrate carbonyl reactant and an amine reactant.

It should also be understood that the binders described herein may be made from melanoidin reactant compounds themselves. That is, once the Maillard reactants are mixed, this mixture can function as a binder of the present invention. These binders may be utilized to fabricate uncured, formaldehyde-free matter, such as fibrous materials.

In the alternative, a binder made from the reactants of a Maillard reaction may be cured. These binders may be used to fabricate cured formaldehyde-free matter, such as, fibrous compositions. These compositions may be water-resistant and, as indicated above, may include water-insoluble melanoidins.

It should be appreciated that the binders described herein may be used in manufacturing products from a collection of non-assembled or loosely-assembled matter. For example, these binders may be employed to fabricate fiber products. These products may be made from woven or nonwoven fibers. The fibers can be heat-resistant or non heat-resistant fibers or combinations thereof. In one illustrative embodiment, the binders are used to bind glass fibers to make fiberglass. In another illustrative embodiment, the binders are used to make cellulosic compositions. With respect to cellulosic compositions, the binders may be used to bind cellulosic matter to fabricate, for example, wood fiber board which has desirable physical properties (e.g., mechanical strength).

One embodiment of the invention is directed to a method for manufacturing products from a collection of non-assembled or loosely-assembled matter. One example of using this method is in the fabrication of fiberglass. However, as indicated above this method can be utilized in the fabrication of any material, as long as the method produces or promotes cohesion when utilized. The method may include contacting the fibers with a thermally-curable, aqueous binder. The binder may include (i) an ammonium salt of a polycarboxylic acid reactant and (ii) a reducing-sugar carbohydrate reactant. These two reactants are melanoidin reactant compounds (i.e., these reactants produce melanoidins when reacted under conditions to initiate a Maillard reaction). The method can further include removing water from the binder in contact with the fibers (i.e., the binder is dehydrated). The method can also include curing the binder in contact with the glass fibers (e.g., thermally curing the binder).

Another example of utilizing this method is in the fabrication of cellulosic materials. The method may include contacting the cellulosic material (e.g., cellulose fibers) with a thermally-curable, aqueous binder. The binder may include (i) an ammonium salt of a polycarboxylic acid reactant and (ii) a reducing-sugar carbohydrate reactant. As indicated above, these two reactants are melanoidin reactant compounds. The method can also include removing water from the binder in contact with the cellulosic material (i.e., the binder is dehydrated). As before, the method can also include curing the binder (e.g., thermal curing).

One way of using the binders is to bind glass fibers together such that they become organized into a fiberglass mat. The mat of fiberglass may be processed to form one of several types of fiberglass materials, such as fiberglass insulation. In one example, the fiberglass material may have glass fibers present in the range from about 75% to about 99% by weight. The uncured binder may function to hold the glass fibers together. Alternatively, the cured binder may function to hold the glass fibers together.

In addition, a fibrous product is described that includes a binder in contact with cellulose fibers, such as those in a mat of wood shavings or sawdust. The mat may be processed to form one of several types of wood fiber board products. In one variation, the binder is uncured. In this variation, the uncured binder may function to hold the cellulosic fibers together. In the alternative, the cured binder may function to hold the cellulosic fibers together.

Also described herein are illustrative embodiments of uncured and cured binders of the present invention used as glass fiber binders in a variety of uncured and cured fiberglass insulation products, respectively.

Additional features of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of illustrative embodiments exemplifying the best mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a number of illustrative reactants for producing melanoidins;

FIG. 2 illustrates a Maillard reaction schematic when reacting a reducing sugar with an amino compound;

FIG. 3 shows the FT-IR spectrum of an illustrative embodiment of a dried binder of the present disclosure;

FIG. 4 shows the FT-IR spectrum of an illustrative embodiment of a cured binder of the present disclosure;

FIG. 5 shows the 650° F. hot surface performance of a fiberglass pipe insulation material fabricated with an illustrative embodiment of a binder of the present disclosure;

FIG. 6 shows the 1000° F. hot surface performance of a fiberglass pipe insulation material fabricated with an illustrative embodiment of a binder of the present disclosure; and

FIG. 7 shows an exemplary schematic that depicts one way of disposing a binder onto fibers.

DETAILED DESCRIPTION

While the invention is susceptible to various modifications and alternative forms, specific embodiments will herein be described in detail. It should be understood, however, that there is no intent to limit the invention to the particular forms described, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

As used herein, the phrase “formaldehyde-free” means that a binder or a material that incorporates a binder liberates less than about 1 ppm formaldehyde as a result of drying and/or curing. The 1 ppm is based on the weight of sample being measured for formaldehyde release.

Cured indicates that the binder has been exposed to conditions so as to initiate a chemical change. Examples of these chemical changes include, but are not limited to, (i) covalent bonding, (ii) hydrogen bonding of binder components, and (iii) chemically cross-linking the polymers and/or oligomers in the binder. These changes may increase the binder's durability and solvent resistance as compared to the uncured binder. Curing a binder may result in the formation of a thermoset material. Furthermore, curing may include the generation of melanoidins. These melanoidins may be generated from a Maillard reaction from melanoidin reactant compounds. In addition, a cured binder may result in an increase in adhesion between the matter in a collection as compared to an uncured binder. Curing can be initiated by, for example, heat, microwave radiation, and/or conditions that initiate one or more of the chemical changes mentioned above.

In a situation where the chemical change in the binder results in the release of water, e.g., polymerization and cross-linking, a cure can be determined by the amount of water released above that which would occur from drying alone. The techniques used to measure the amount of water released during drying as compared to when a binder is cured, are well known in the art.

In accordance with the above paragraph, an uncured binder is one that has not been cured.

As used herein, the term “alkaline” indicates a solution having a pH that is greater than or equal to about 7. For example, the pH of the solution can be less than or equal to about 10. In addition, the solution may have a pH from about 7 to about 10, or from about 8 to about 10, or from about 9 to about 10.

As used herein, the term “ammonium” includes, but is not limited to, ⁺NH₄, ⁺NH₃R¹, and ⁺NH₂R¹R², where R¹ and R² are each independently selected in ⁺NH₂R¹R², and where R¹ and R² are selected from alkyl, cycloalkyl, alkenyl, cycloalkenyl, heterocyclyl, aryl, and heteroaryl.

The term “alkyl” refers to a saturated monovalent chain of carbon atoms, which may be optionally branched; the term “cycloalkyl” refers to a monovalent chain of carbon atoms, a portion of which forms a ring; the term “alkenyl” refers to an unsaturated monovalent chain of carbon atoms including at least one double bond, which may be optionally branched; the term “cycloalkenyl” refers to an unsaturated monovalent chain of carbon atoms, a portion of which forms a ring; the term “heterocyclyl” refers to a monovalent chain of carbon and heteroatoms, wherein the heteroatoms are selected from nitrogen, oxygen, and sulfur, a portion of which, including at least one heteroatom, form a ring; the term “aryl” refers to an aromatic mono or polycyclic ring of carbon atoms, such as phenyl, naphthyl, and the like; and the term “heteroaryl” refers to an aromatic mono or polycyclic ring of carbon atoms and at least one heteroatom selected from nitrogen, oxygen, and sulfur, such as pyridinyl, pyrimidinyl, indolyl, benzoxazolyl, and the like. It is to be understood that each of alkyl, cycloalkyl, alkenyl, cycloalkenyl, and heterocyclyl may be optionally substituted with independently selected groups such as alkyl, haloalkyl, hydroxyalkyl, aminoalkyl, carboxylic acid and derivatives thereof, including esters, amides, and nitriles, hydroxy, alkoxy, acyloxy, amino, alkyl and dialkylamino, acylamino, thio, and the like, and combinations thereof. It is further to be understood that each of aryl and heteroaryl may be optionally substituted with one or more independently selected substituents, such as halo, hydroxy, amino, alkyl or dialkylamino, alkoxy, alkylsulfonyl, cyano, nitro, and the like.

As used herein, the term “polycarboxylic acid” indicates a dicarboxylic, tricarboxylic, tetracarboxylic, pentacarboxylic, and like monomeric polycarboxylic acids, and anhydrides, and combinations thereof, as well as polymeric polycarboxylic acids, anhydrides, copolymers, and combinations thereof. In one aspect, the polycarboxylic acid ammonium salt reactant is sufficiently non-volatile to maximize its ability to remain available for reaction with the carbohydrate reactant of a Maillard reaction (discussed below). In another aspect, the polycarboxylic acid ammonium salt reactant may be substituted with other chemical functional groups.

Illustratively, a monomeric polycarboxylic acid may be a dicarboxylic acid, including, but not limited to, unsaturated aliphatic dicarboxylic acids, saturated aliphatic dicarboxylic acids, aromatic dicarboxylic acids, unsaturated cyclic dicarboxylic acids, saturated cyclic dicarboxylic acids, hydroxy-substituted derivatives thereof, and the like. Or, illustratively, the polycarboxylic acid itself may be a tricarboxylic acid, including, but not limited to, unsaturated aliphatic tricarboxylic acids, saturated aliphatic tricarboxylic acids, aromatic tricarboxylic acids, unsaturated cyclic tricarboxylic acids, saturated cyclic tricarboxylic acids, hydroxy-substituted derivatives thereof, and the like. It is appreciated that any such polycarboxylic acids may be optionally substituted, such as with hydroxy, halo, alkyl, alkoxy, and the like. In one variation, the polycarboxylic acid is the saturated aliphatic tricarboxylic acid, citric acid. Other suitable polycarboxylic acids are contemplated to include, but are not limited to, aconitic acid, adipic acid, azelaic acid, butane tetracarboxylic acid dihydride, butane tricarboxylic acid, chlorendic acid, citraconic acid, dicyclopentadiene-maleic acid adducts, diethylenetriamine pentaacetic acid, adducts of dipentene and maleic acid, ethylenediamine tetraacetic acid (EDTA), fully maleated rosin, maleated tall-oil fatty acids, fumaric acid, glutaric acid, isophthalic acid, itaconic acid, maleated rosin oxidized with potassium peroxide to alcohol then carboxylic acid, maleic acid, malic acid, mesaconic acid, biphenol A or bisphenol F reacted via the KOLBE-Schmidt reaction with carbon dioxide to introduce 3-4 carboxyl groups, oxalic acid, phthalic acid, sebacic acid, succinic acid, tartaric acid, terephthalic acid, tetrabromophthalic acid, tetrachlorophthalic acid, tetrahydrophthalic acid, trimellitic acid, trimesic acid, and the like, and anhydrides, and combinations thereof.

Illustratively, a polymeric polycarboxylic acid may be an acid, including, but not limited to, polyacrylic acid, polymethacrylic acid, polymaleic acid, and like polymeric polycarboxylic acids, anhydrides thereof, and mixtures thereof, as well as copolymers of acrylic acid, methacrylic acid, maleic acid, and like carboxylic acids, anhydrides thereof, and mixtures thereof. Examples of commercially available polyacrylic acids include AQUASET-529 (Rohm & Haas, Philadelphia, Pa., USA), CRITERION 2000 (Kemira, Helsinki, Finland, Europe), NF1 (H. B. Fuller, St. Paul, Minn., USA), and SOKALAN (BASF, Ludwigshafen, Germany, Europe). With respect to SOKALAN, this is a water-soluble polyacrylic copolymer of acrylic acid and maleic acid, having a molecular weight of approximately 4000. AQUASET-529 is a composition containing polyacrylic acid cross-linked with glycerol, also containing sodium hypophosphite as a catalyst. CRITERION 2000 is an acidic solution of a partial salt of polyacrylic acid, having a molecular weight of approximately 2000. With respect to NF1, this is a copolymer containing carboxylic acid functionality and hydroxy functionality, as well as units with neither functionality; NF1 also contains chain transfer agents, such as sodium hypophosphite or organophosphate catalysts.

Further, compositions including polymeric polycarboxylic acids are also contemplated to be useful in preparing the binders described herein, such as those compositions described in U.S. Pat. Nos. 5,318,990, 5,661,213, 6,136,916, and 6,331,350, the disclosures of which are hereby incorporated herein by reference. Described in U.S. Pat. Nos. 5,318,990 and 6,331,350 are compositions comprising an aqueous solution of a polymeric polycarboxylic acid, a polyol, and a catalyst.

As described in U.S. Pat. Nos. 5,318,990 and 6,331,350, the polymeric polycarboxylic acid comprises an organic polymer or oligomer containing more than one pendant carboxy group. The polymeric polycarboxylic acid may be a homopolymer or copolymer prepared from unsaturated carboxylic acids including, but not necessarily limited to, acrylic acid, methacrylic acid, crotonic acid, isocrotonic acid, maleic acid, cinnamic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaconic acid, α,β-methyleneglutaric acid, and the like. Alternatively, the polymeric polycarboxylic acid may be prepared from unsaturated anhydrides including, but not necessarily limited to, maleic anhydride, itaconic anhydride, acrylic anhydride, methacrylic anhydride, and the like, as well as mixtures thereof. Methods for polymerizing these acids and anhydrides are well-known in the chemical art. The polymeric polycarboxylic acid may additionally comprise a copolymer of one or more of the aforementioned unsaturated carboxylic acids or anhydrides and one or more vinyl compounds including, but not necessarily limited to, styrene, α-methylstyrene, acrylonitrile, methacrylonitrile, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, methyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, glycidyl methacrylate, vinyl methyl ether, vinyl acetate, and the like. Methods for preparing these copolymers are well-known in the art. The polymeric polycarboxylic acids may comprise homopolymers and copolymers of polyacrylic acid. The molecular weight of the polymeric polycarboxylic acid, and in particular polyacrylic acid polymer, may be is less than 10000, less than 5000, or about 3000 or less. For example, the molecular weight may be 2000.

As described in U.S. Pat. Nos. 5,318,990 and 6,331,350, the polyol (in a composition including a polymeric polycarboxylic acid) contains at least two hydroxyl groups. The polyol should be sufficiently nonvolatile such that it will substantially remain available for reaction with the polymeric polycarboxylic acid in the composition during heating and curing operations. The polyol may be a compound with a molecular weight less than about 1000 bearing at least two hydroxyl groups such as, ethylene glycol, glycerol, pentaerythritol, trimethylol propane, sorbitol, sucrose, glucose, resorcinol, catechol, pyrogallol, glycollated ureas, 1,4-cyclohexane diol, diethanolamine, triethanolamine, and certain reactive polyols, for example, β-hydroxyalkylamides such as, for example, bis[N,N-di(β-hydroxyethyl)]adipamide, or it may be an addition polymer containing at least two hydroxyl groups such as, polyvinyl alcohol, partially hydrolyzed polyvinyl acetate, and homopolymers or copolymers of hydroxyethyl(meth)acrylate, hydroxypropyl(meth)acrylate, and the like.

As described in U.S. Pat. Nos. 5,318,990 and 6,331,350, the catalyst (in a composition including a polymeric polycarboxylic acid) is a phosphorous-containing accelerator which may be a compound with a molecular weight less than about 1000 such as, an alkali metal polyphosphate, an alkali metal dihydrogen phosphate, a polyphosphoric acid, and an alkyl phosphinic acid or it may be an oligomer or polymer bearing phosphorous-containing groups, for example, addition polymers of acrylic and/or maleic acids formed in the presence of sodium hypophosphite, addition polymers prepared from ethylenically unsaturated monomers in the presence of phosphorous salt chain transfer agents or terminators, and addition polymers containing acid-functional monomer residues, for example, copolymerized phosphoethyl methacrylate, and like phosphonic acid esters, and copolymerized vinyl sulfonic acid monomers, and their salts. The phosphorous-containing accelerator may be used at a level of from about 1% to about 40%, by weight based on the combined weight of the polymeric polycarboxylic acid and the polyol. A level of phosphorous-containing accelerator of from about 2.5% to about 10%, by weight based on the combined weight of the polymeric polycarboxylic acid and the polyol may be used. Examples of such catalysts include, but are not limited to, sodium hypophosphite, sodium phosphite, potassium phosphite, disodium pyrophosphate, tetrasodium pyrophosphate, sodium tripolyphosphate, sodium hexametaphosphate, potassium phosphate, potassium polymetaphosphate, potassium polyphosphate, potassium tripolyphosphate, sodium trimetaphosphate, and sodium tetrametaphosphate, as well as mixtures thereof.

Compositions including polymeric polycarboxylic acids described in U.S. Pat. Nos. 5,661,213 and 6,136,916 that are contemplated to be useful in preparing the binders described herein comprise an aqueous solution of a polymeric polycarboxylic acid, a polyol containing at least two hydroxyl groups, and a phosphorous-containing accelerator, wherein the ratio of the number of equivalents of carboxylic acid groups to the number of equivalents of hydroxyl groups is from about 1:0.01 to about 1:3

As described in U.S. Pat. Nos. 5,661,213 and 6,136,916, the polymeric polycarboxylic acid may be a polyester containing at least two carboxylic acid groups or an addition polymer or oligomer containing at least two copolymerized carboxylic acid-functional monomers. The polymeric polycarboxylic acid is preferably an addition polymer formed from at least one ethylenically unsaturated monomer. The addition polymer may be in the form of a solution of the addition polymer in an aqueous medium such as, an alkali-soluble resin which has been solubilized in a basic medium; in the form of an aqueous dispersion, for example, an emulsion-polymerized dispersion; or in the form of an aqueous suspension. The addition polymer must contain at least two carboxylic acid groups, anhydride groups, or salts thereof. Ethylenically unsaturated carboxylic acids such as, methacrylic acid, acrylic acid, crotonic acid, fumaric acid, maleic acid, 2-methyl maleic acid, itaconic acid, 2-methyl itaconic acid, α,β-methylene glutaric acid, monoalkyl maleates, and monoalkyl fumarates; ethylenically unsaturated anhydrides, for example, maleic anhydride, itaconic anhydride, acrylic anhydride, and methacrylic anhydride; and salts thereof, at a level of from about 1% to 100%, by weight, based on the weight of the addition polymer, may be used. Additional ethylenically unsaturated monomers may include acrylic ester monomers including methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, decyl acrylate, methyl methacrylate, butyl methacrylate, isodecyl methacrylate, hydroxyethyl acrylate, hydroxyethyl methacrylate, and hydroxypropyl methacrylate; acrylamide or substituted acrylamides; styrene or substituted styrenes; butadiene; vinyl acetate or other vinyl esters; acrylonitrile or methacrylonitrile; and the like. The addition polymer containing at least two carboxylic acid groups, anhydride groups, or salts thereof may have a molecular weight from about 300 to about 10,000,000. A molecular weight from about 1000 to about 250,000 may be used. When the addition polymer is an alkali-soluble resin having a carboxylic acid, anhydride, or salt thereof, content of from about 5% to about 30%, by weight based on the total weight of the addition polymer, a molecular weight from about 10,000 to about 100,000 may be utilized Methods for preparing these additional polymers are well-known in the art.

As described in U.S. Pat. Nos. 5,661,213 and 6,136,916, the polyol (in a composition including a polymeric polycarboxylic acid) contains at least two hydroxyl groups and should be sufficiently nonvolatile that it remains substantially available for reaction with the polymeric polycarboxylic acid in the composition during heating and curing operations. The polyol may be a compound with a molecular weight less than about 1000 bearing at least two hydroxyl groups, for example, ethylene glycol, glycerol, pentaerythritol, trimethylol propane, sorbitol, sucrose, glucose, resorcinol, catechol, pyrogallol, glycollated ureas, 1,4-cyclohexane diol, diethanolamine, triethanolamine, and certain reactive polyols, for example, β-hydroxyalkylamides, for example, bis-MN-di(β-hydroxyethyl)]adipamide, bis[N,N-di(β-hydroxypropyl)] azelamide, bis[N—N-di(β-hydroxypropyl)] adipamide, bis[N—N-di(β-hydroxypropyl)] glutaramide, bis[N—N-di(β-hydroxypropyl)] succinamide, and bis[N-methyl-N-(β-hydroxyethyl)] oxamide, or it may be an addition polymer containing at least two hydroxyl groups such as, polyvinyl alcohol, partially hydrolyzed polyvinyl acetate, and homopolymers or copolymers of hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate, and the like.

As described in U.S. Pat. Nos. 5,661,213 and 6,136,916, the phosphorous-containing accelerator (in a composition including a polymeric polycarboxylic acid) may be a compound with a molecular weight less than about 1000, such as an alkali metal hypophosphite salt, an alkali metal phosphite, an alkali metal polyphosphate, an alkali metal dihydrogen phosphate, a polyphosphoric acid, and an alkyl phosphinic acid, or it may be an oligomer or polymer bearing phosphorous-containing groups such as addition polymers of acrylic and/or maleic acids formed in the presence of sodium hypophosphite, addition polymers prepared from ethylenically unsaturated monomers in the presence of phosphorous salt chain transfer agents or terminators, and addition polymers containing acid-functional monomer residues such as, copolymerized phosphoethyl methacrylate, and like phosphonic acid esters, and copolymerized vinyl sulfonic acid monomers, and their salts. The phosphorous-containing accelerator may be used at a level of from about 1% to about 40%, by weight based on the combined weight of the polyacid and the polyol. A level of phosphorous-containing accelerator of from about 2.5% to about 10%, by weight based on the combined weight of the polyacid and the polyol, may be utilized.

As used herein, the term “amine base” includes, but is not limited to, ammonia, a primary amine, i.e., NH₂R¹, and a secondary amine, i.e., NHR¹R², where R¹ and R² are each independently selected in NHR¹R², and where R¹ and R² are selected from alkyl, cycloalkyl, alkenyl, cycloalkenyl, heterocyclyl, aryl, and heteroaryl, as defined herein. Illustratively, the amine base may be substantially volatile or substantially non-volatile under conditions sufficient to promote formation of the thermoset binder during thermal curing. Illustratively, the amine base may be a substantially volatile base, such as ammonia, ethylamine, diethylamine, dimethylamine, ethylpropylamine, and the like. Alternatively, the amine base may be a substantially non-volatile base, such as aniline, 1-naphthylamine, 2-naphthylamine, para-aminophenol, and the like.

As used herein, “reducing sugar” indicates one or more sugars that contain aldehyde groups, or that can isomerize, i.e., tautomerize, to contain aldehyde groups, which groups are reactive with an amino group under Maillard reaction conditions and which groups may be oxidized with, for example, Cu′ to afford carboxylic acids. It is also appreciated that any such carbohydrate reactant may be optionally substituted, such as with hydroxy, halo, alkyl, alkoxy, and the like. It is further appreciated that in any such carbohydrate reactant, one or more chiral centers are present, and that both possible optical isomers at each chiral center are contemplated to be included in the invention described herein. Further, it is also to be understood that various mixtures, including racemic mixtures, or other diastereomeric mixtures of the various optical isomers of any such carbohydrate reactant, as well as various geometric isomers thereof, may be used in one or more embodiments described herein.

As used herein, the term “fiberglass” indicates heat-resistant fibers suitable for withstanding elevated temperatures. Examples of such fibers include, but are not limited to, mineral fibers (e.g., rock fibers), aramid fibers, ceramic fibers, metal fibers, carbon fibers, polyimide fibers, certain polyester fibers, rayon fibers, mineral wool (e.g., glass wool or rock wool), and glass fibers. Illustratively, such fibers are substantially unaffected by exposure to temperatures above about 120° C.

FIG. 1 shows examples of reactants for a Maillard reaction. Examples of amine reactants include proteins, peptides, amino acids, ammonium salts of polymeric polycarboxylic acids, and ammonium salts of monomeric polycarboxylic acids. As illustrated, “ammonium” can be [NH₄]_(x), [⁺NH₃R¹]_(x), and [⁺NH₂R¹R²]_(x), where x is at least about 1. With respect to ⁺NH₂R¹R², R¹ and R² are each independently selected. Moreover, R¹ and R² are selected from alkyl, cycloalkyl, alkenyl, cycloalkenyl, heterocyclyl, aryl, and heteroaryl, as described above. FIG. 1 also illustrates examples of reducing-sugar reactants for producing melanoidins, including monosaccharides, in their aldose or ketose form, polysaccharides, or combinations thereof. Illustrative non-carbohydrate carbonyl reactants for producing melanoidins are also shown in FIG. 1, and include various aldehydes, e.g., pyruvaldehyde and furfural, as well as compounds such as ascorbic acid and quinone.

FIG. 2 shows a schematic of a Maillard reaction, which culminates in the production of melanoidins. In its initial phase, a Maillard reaction involves a carbohydrate reactant, for example, a reducing or aldose sugar (note that the carbohydrate reactant may come from a substance capable of producing a reducing sugar under Maillard reaction conditions). The reaction also involves condensing the carbohydrate reactant (e.g., a reducing or aldose sugar) with an amine reactant, e.g., an amino compound possessing an amino group. In other words, the carbohydrate reactant and the amine reactant for a Maillard reaction are the melanoidin reactant compounds. The condensation of these two reactants produces an N-substituted glycosylamine. For a more detailed description of the Maillard reaction see, Hodge, J. E. Chemistry of Browning Reactions in Model Systems J. Agric. Food Chem. 1953, 1, 928-943, the disclosure of which is hereby incorporated herein by reference. The compound possessing a free amino group in a Maillard reaction, which compound serves as the amine reactant, may be present in the form of an amino acid. The free amino group can also come from a protein, where the free amino groups are available in the form of, for example, the ε-amino group of lysine residues, and/or the α-amino group of the terminal amino acid. Alternatively, as described herein, an ammonium salt of a polycarboxylic acid may serve as the amine reactant in a Maillard reaction.

Another aspect of conducting a Maillard reaction as described herein is that, initially, the aqueous Maillard reactant solution (which also is a binder), as described above, has an alkaline pH. However, once the solution is disposed on a collection of non-assembled or loosely-assembled matter, and curing is initiated, the pH decreases (i.e., the binder becomes acidic). It should be understood that when fabricating a material, the amount of contact between the binder and components of machinery used in the fabrication is greater prior to curing, (i.e., when the binder solution is alkaline) as compared to after the binder is cured (i.e., when the binder is acidic). An alkaline composition is less corrosive than an acidic composition. Accordingly, corrosivity of the fabrication process is decreased.

It should be appreciated that by using the aqueous Maillard reactant solution described herein, the machinery used to fabricate fiberglass is not exposed to an acidic solution because, as described above, the pH of the Maillard reactant solution is alkaline. Furthermore, during the fabrication process, the only time an acidic condition develops is after the binder has been applied to glass fibers. Once the binder is applied to the glass fibers, the binder and the material that incorporates the binder have relatively infrequent contact with the components of the machinery, as compared to the time prior to applying the binder to the glass fibers. Accordingly, corrosivity of fiberglass fabrication (and the fabrication of other materials) is decreased.

Without being bound to theory, covalent reaction of the polycarboxylic acid ammonium salt and reducing sugar reactants of a Maillard reaction, which as described herein occurs substantially during thermal curing to produce brown-colored nitrogenous polymeric and co-polymeric melanoidins of varying structure, is thought to involve initial Maillard reaction of ammonia with the aldehyde moiety of a reducing-sugar carbohydrate reactant to afford N-substituted glycosylamine, as shown in FIG. 2. Consumption of ammonia in such a way, with ammonia and a reducing-sugar carbohydrate reactant combination functioning as a latent acid catalyst, would be expected to result in a decrease in pH, which decrease is believed to promote esterification processes and/or dehydration of the polycarboxylic acid to afford its corresponding anhydride derivative. At pH≤7, the Amadori rearrangement product of N-substituted glycosylamine, i.e., 1-amino-1-deoxy-2-ketose, would be expected to undergo mainly 1,2-enolization with the formation of furfural when, for example, pentoses are involved, or hydroxymethylfurfural when, for example, hexoses are involved, as a prelude to melanoidin production. Concurrently, contemporaneously, or sequentially with the production of melanoidins, esterification processes may occur involving melanoidins, polycarboxylic acid and/or its corresponding anhydride derivative, and residual carbohydrate, which processes lead to extensive cross-linking. Accompanied by sugar dehydration reactions, whereupon conjugated double bonds are produced that may undergo polymerization, a water-resistant thermoset binder is produced consisting of polyester adducts interconnected by a network of carbon-carbon single bonds. Consistent with the above reaction scenario is a strong absorbance near 1734 cm⁻¹ in the FT-IR spectrum of a cured binder described herein, which absorbance is within the 1750-1730 cm⁻¹ range expected for ester carbonyl C—O vibrations. The afore-mentioned spectrum is shown in FIG. 4.

FIG. 7 is an exemplary schematic showing one embodiment of a process for disposing a binder of the present invention onto a substrate such as glass fibers. In particular, as shown in FIG. 7, silica (sand) particles 10 are placed in the interior 12 of a vat 14, where the particles 10 are moltenized to produce molten glass 16. Molten glass 16 is then advanced through a fiberizer 18 so as to fiberize molten glass 16 into glass fibers 20. A container 22 that contains a liquid uncured binder 24 of the present invention is in fluid communication with fiberizer 18 and disposes the liquid uncured binder 24 onto glass fibers 20 so as to bind the fibers together. Glass fibers 20 are placed onto a forming chain 26 so as to form a collection 38 of glass fibers 20. The collection 38 is then advanced in the direction indicated by arrow 28 so as to enter oven 30 where the collection is heated and curing occurs. While positioned in oven 30, collection 38 is positioned between flights 32 and 34. Flight 32 can be moved relative to flight 34 in the direction indicated by arrow 36, i.e., flight 32 can be positioned closer to flight 34 or moved away from flight 34 thereby adjusting the distance between flights 32 and 34. As shown in FIG. 7, flight 32 has been moved relative to flight 34 so as to exert a compressive force on collection 38 as it moves through the oven 30. Subjecting the collection 38 to a compressive force decreases the thickness of collection 38 as compared to its thickness prior to encountering flights 32 and 34. Accordingly, the density of the collection 38 is increased as compared to its density prior to encountering flights 32 and 34. As mentioned above, the collection 38 is heated in the oven 30 and curing occurs so as to produce a cured binder 40 being disposed on glass fibers 20. The curing may result in a thermoset binder material being disposed upon glass fibers 22. The collection 38 then exits oven 30 where it can be utilized in various products, e.g., products described herein, such as, acoustical board, pipe insulation, batt residential insulation, and elevated panel insulation to name a few.

The above description sets forth one example of how to adjust a process parameter to obtain one or more desirable physical/chemical characteristics of a collection bound together by a binder of the present invention, e.g., the thickness and density of the collection is altered as it passes through the oven. However, it should be appreciated that a number of other parameters (one or more) can also be adjusted to obtain desirable characteristics. These include the amount of binder applied onto the glass fibers, the type of silica utilized to make the glass fibers, the size of the glass fibers (e.g., fiber diameter, fiber length and fiber thickness) that make up a collection. What the desirable characteristic are will depend upon the type of product being manufactured, e.g., acoustical board, pipe insulation, batt residential insulation, and elevated panel insulation to name a few. The desirable characteristics associated with any particular product are well known in the art. With respect to what process parameters to manipulate and how they are manipulated to obtain the desirable physical/chemical characteristics, e.g., thermal properties and acoustical characteristics, these can be determined by routine experimentation. For example, a collection having a greater density is desirable when fabricating acoustical board as compared with the density required when fabricating residential insulation.

The following discussion is directed to (i) examples of carbohydrate and amine reactants, which reactants can be used in a Maillard reaction, (ii) how these reactants can be combined with each other and with various additives to prepare binders of the present invention, and iii) illustrative embodiments of the binders described herein used as glass fiber binders in fiberglass insulation products and as cellulosic fiber binders in wood fiber board products. First, it should be understood that any carbohydrate and any compound possessing a primary or secondary amino group, which will act as a reactant in a Maillard reaction, can be utilized in the binders of the present invention. Such compounds can be identified and utilized by one of ordinary skill in the art with the guidelines disclosed herein.

With respect to exemplary reactants, it should also be appreciated that using an ammonium salt of a polycarboxylic acid as an amine reactant is an effective reactant in a Maillard reaction. Ammonium salts of polycarboxylic acids can be generated by neutralizing the acid groups with an amine base, thereby producing polycarboxylic acid ammonium salt groups. Complete neutralization, i.e., about 100% calculated on an equivalents basis, may eliminate any need to titrate or partially neutralize acid groups in the polycarboxylic acid prior to binder formation. However, it is expected that less-than-complete neutralization would not inhibit formation of the binder. Note that neutralization of the acid groups of the polycarboxylic acid may be carried out either before or after the polycarboxylic acid is mixed with the carbohydrate.

With respect to the carbohydrate reactant, it may include one or more reactants having one or more reducing sugars. In one aspect, any carbohydrate reactant should be sufficiently nonvolatile to maximize its ability to remain available for reaction with the polycarboxylic acid ammonium salt reactant. The carbohydrate reactant may be a monosaccharide in its aldose or ketose form, including a triose, a tetrose, a pentose, a hexose, or a heptose; or a polysaccharide; or combinations thereof. A carbohydrate reactant may be a reducing sugar, or one that yields one or more reducing sugars in situ under thermal curing conditions. For example, when a triose serves as the carbohydrate reactant, or is used in combination with other reducing sugars and/or a polysaccharide, an aldotriose sugar or a ketotriose sugar may be utilized, such as glyceraldehyde and dihydroxyacetone, respectively. When a tetrose serves as the carbohydrate reactant, or is used in combination with other reducing sugars and/or a polysaccharide, aldotetrose sugars, such as erythrose and threose; and ketotetrose sugars, such as erythrulose, may be utilized. When a pentose serves as the carbohydrate reactant, or is used in combination with other reducing sugars and/or a polysaccharide, aldopentose sugars, such as ribose, arabinose, xylose, and lyxose; and ketopentose sugars, such as ribulose, arabulose, xylulose, and lyxulose, may be utilized. When a hexose serves as the carbohydrate reactant, or is used in combination with other reducing sugars and/or a polysaccharide, aldohexose sugars, such as glucose (i.e., dextrose), mannose, galactose, allose, altrose, talose, gulose, and idose; and ketohexose sugars, such as fructose, psicose, sorbose and tagatose, may be utilized. When a heptose serves as the carbohydrate reactant, or is used in combination with other reducing sugars and/or a polysaccharide, a ketoheptose sugar such as sedoheptulose may be utilized. Other stereoisomers of such carbohydrate reactants not known to occur naturally are also contemplated to be useful in preparing the binder compositions as described herein. When a polysaccharide serves as the carbohydrate, or is used in combination with monosaccharides, sucrose, lactose, maltose, starch, and cellulose may be utilized.

Furthermore, the carbohydrate reactant in the Maillard reaction may be used in combination with a non-carbohydrate polyhydroxy reactant. Examples of non-carbohydrate polyhydroxy reactants which can be used in combination with the carbohydrate reactant include, but are not limited to, trimethylolpropane, glycerol, pentaerythritol, sorbitol, 1,5-pentanediol, 1,6-hexanediol, polyTHF₆₅₀, polyTHF₂₅₀, textrion whey, polyvinyl alcohol, partially hydrolyzed polyvinyl acetate, fully hydrolyzed polyvinyl acetate, and mixtures thereof. In one aspect, the non-carbohydrate polyhydroxy reactant is sufficiently nonvolatile to maximize its ability to remain available for reaction with a monomeric or polymeric polycarboxylic acid reactant. It is appreciated that the hydrophobicity of the non-carbohydrate polyhydroxy reactant may be a factor in determining the physical properties of a binder prepared as described herein.

When a partially hydrolyzed polyvinyl acetate serves as a non-carbohydrate polyhydroxy reactant, a commercially available compound such as an 87-89% hydrolyzed polyvinyl acetate may be utilized, such as, DuPont ELVANOL 51-05. DuPont ELVANOL 51-05 has a molecular weight of about 22,000-26,000 Da and a viscosity of about 5.0-6.0 centipoises. Other partially hydrolyzed polyvinyl acetates contemplated to be useful in preparing binder compositions as described herein include, but are not limited to, 87-89% hydrolyzed polyvinyl acetates differing in molecular weight and viscosity from ELVANOL 51-05, such as, for example, DuPont ELVANOL 51-04, ELVANOL 51-08, ELVANOL 50-14, ELVANOL 52-22, ELVANOL 50-26, ELVANOL 50-42; and partially hydrolyzed polyvinyl acetates differing in molecular weight, viscosity, and/or degree of hydrolysis from ELVANOL 51-05, such as, DuPont ELVANOL 51-03 (86-89% hydrolyzed), ELVANOL 70-14 (95.0-97.0% hydrolyzed), ELVANOL 70-27 (95.5-96.5% hydrolyzed), ELVANOL 60-30 (90-93% hydrolyzed). Other partially hydrolyzed polyvinyl acetates contemplated to be useful in preparing binder compositions as described herein include, but are not limited to, Clariant MOWIOL 15-79, MOWIOL 3-83, MOWIOL 4-88, MOWIOL 5-88, MOWIOL 8-88, MOWIOL 18-88, MOWIOL 23-88, MOWIOL 26-88, MOWIOL 40-88, MOWIOL 47-88, and MOWIOL 30-92, as well as Celanese CELVOL 203, CELVOL 205, CELVOL 502, CELVOL 504, CELVOL 513, CELVOL 523, CELVOL 523TV, CELVOL 530, CELVOL 540, CELVOL 540TV, CELVOL 418, CELVOL 425, and CELVOL 443. Also contemplated to be useful are similar or analogous partially hydrolyzed polyvinyl acetates available from other commercial suppliers.

When a fully hydrolyzed polyvinyl acetate serves as a non-carbohydrate polyhydroxy reactant, Clariant MOWIOL 4-98, having a molecular weight of about 27,000 Da, may be utilized. Other fully hydrolyzed polyvinyl acetates contemplated to be useful include, but are not limited to, DuPont ELVANOL 70-03 (98.0-98.8% hydrolyzed), ELVANOL 70-04 (98.0-98.8% hydrolyzed), ELVANOL 70-06 (98.5-99.2% hydrolyzed), ELVANOL 90-50 (99.0-99.8% hydrolyzed), ELVANOL 70-20 (98.5-99.2% hydrolyzed), ELVANOL 70-30 (98.5-99.2% hydrolyzed), ELVANOL 71-30 (99.0-99.8% hydrolyzed), ELVANOL 70-62 (98.4-99.8% hydrolyzed), ELVANOL 70-63 (98.5-99.2% hydrolyzed), ELVANOL 70-75 (98.5-99.2% hydrolyzed), Clariant MOWIOL 3-98, MOWIOL 6-98, MOWIOL 10-98, MOWIOL 20-98, MOWIOL 56-98, MOWIOL 28-99, and Celanese CELVOL 103, CELVOL 107, CELVOL 305, CELVOL 310, CELVOL 325, CELVOL 325LA, and CELVOL 350, as well as similar or analogous fully hydrolyzed polyvinyl acetates from other commercial suppliers.

The aforementioned Maillard reactants may be combined to make an aqueous composition that includes a carbohydrate reactant and an amine reactant. These aqueous binders represent examples of uncured binders. As discussed below, these aqueous compositions can be used as binders of the present invention. These binders are formaldehyde-free, curable, alkaline, aqueous binder compositions. Furthermore, as indicated above, the carbohydrate reactant of the Maillard reactants may be used in combination with a non-carbohydrate polyhydroxy reactant. Accordingly, any time the carbohydrate reactant is mentioned, it should be understood that it can be used in combination with a non-carbohydrate polyhydroxy reactant.

In one illustrative embodiment, the aqueous solution of Maillard reactants may include (i) an ammonium salt of a polycarboxylic acid reactant and (ii) a carbohydrate reactant having a reducing sugar. The pH of this solution prior to placing it in contact with the material to be bound can be greater than or equal to about 7. In addition, this solution can have a pH of less than or equal to about 10. The ratio of the number of moles of the polycarboxylic acid reactant to the number of moles of the carbohydrate reactant can be in the range from about 1:4 to about 1:15. In one illustrative variation, the ratio of the number of moles of the polycarboxylic acid reactant to the number of moles of the carbohydrate reactant in the binder composition is about 1:5. In another variation, the ratio of the number of moles of the polycarboxylic acid reactant to the number of moles of the carbohydrate reactant is about 1:6. In another variation, the ratio of the number of moles of the polycarboxylic acid reactant to the number of moles of the carbohydrate reactant is about 1:7.

As described above, the aqueous binder composition may include (i) an ammonium salt of a polycarboxylic acid reactant and (ii) a carbohydrate reactant having a reducing sugar. It should be appreciated that when an ammonium salt of a monomeric or a polymeric polycarboxylic acid is used as an amine reactant, the molar equivalents of ammonium ion may or may not be equal to the molar equivalents of acid groups present on the polycarboxylic acid. In one illustrative example, an ammonium salt may be monobasic, dibasic, or tribasic when a tricarboxylic acid is used as a polycarboxylic acid reactant. Thus, the molar equivalents of the ammonium ion may be present in an amount less than or about equal to the molar equivalents of acid groups present in a polycarboxylic acid. Accordingly, the ammonium salt can be monobasic or dibasic when the polycarboxylic acid reactant is a dicarboxylic acid. Further, the molar equivalents of ammonium ion may be present in an amount less than, or about equal to, the molar equivalents of acid groups present in a polymeric polycarboxylic acid, and so on and so forth. When a monobasic salt of a dicarboxylic acid is used, or when a dibasic salt of a tricarboxylic acid is used, or when the molar equivalents of ammonium ions are present in an amount less than the molar equivalents of acid groups present in a polymeric polycarboxylic acid, the pH of the binder composition may require adjustment to achieve alkalinity.

The uncured, formaldehyde-free, thermally-curable, alkaline, aqueous binder composition can be used to fabricate a number of different materials. In particular, these binders can be used to produce or promote cohesion in non-assembled or loosely-assembled matter by placing the binder in contact with the matter to be bound. Any number of well known techniques can be employed to place the aqueous binder in contact with the material to be bound. For example, the aqueous binder can be sprayed on (e.g., during the binding glass fibers) or applied via a roll-coat apparatus.

The aqueous binders described herein can be applied to a mat of glass fibers (e.g., sprayed onto the mat) during production of fiberglass insulation products. Once the aqueous binder is in contact with the glass fibers, the residual heat from the glass fibers (note that the glass fibers are made from molten glass and thus contain residual heat) and the flow of air through the fibrous mat will evaporate (i.e., remove) water from the binder. Removing the water leaves the remaining components of the binder on the fibers as a coating of viscous or semi-viscous high-solids liquid. This coating of viscous or semi-viscous high-solids liquid functions as a binder. At this point, the mat has not been cured. In other words, the uncured binder functions to bind the glass fibers in the mat.

In one illustrative embodiment, the uncured binders described herein can be used as glass fiber binders in uncured fiberglass insulation products exemplified by “ship out” uncured. “Ship out” uncured insulation is manufactured as a rolled-up blanket including glass fibers that are loosely bonded together with a thermosetting binder. This insulation is typically an in-process material, which is shipped in a wet and uncured state to be further processed, usually by compression molding or match metal die molding, and heat curing into components of a desired shape and density for use in transportation, office, appliance, architectural, acoustical, and industrial applications. Thermal and acoustical performance of a molded part depend on part design, thickness, and density. Thickness and/or density of “ship out” uncured are determined in accordance with ASTM C 167. “Ship out” uncured insulation typically requires a nominal moisture content of ±about 4+about 3.0/−about 2.0%, a nominal binder content of about 16±about 2.0%, and a nominal fiber diameter of about 31±about 4 ht.

In one illustrative variation, “ship out” uncured has a nominal density of about 0.8 lbs/ft³ and a nominal weight of about 0.07 lbs/ft², e.g., in some embodiments the nominal weight can be about 0.0669 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 0.9 lbs/ft³ and a nominal weight of about 0.07 lbs/ft², e.g., in some embodiments the nominal density can be about 0.89 lbs/ft³ and the nominal weight can be about 0.0744 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 0.9 lbs/ft³ and a nominal weight of about 0.08 lbs/ft², e.g., in some embodiments the nominal weight can be about 0.0750 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 1.1 lbs/ft³ and a nominal weight of about 0.09 lbs/ft², e.g., in some embodiments the nominal density can be about 1.15 lbs/ft³ and the nominal weight can be about 0.0954 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 1.3 lbs/ft³ and a nominal weight of about 0.1 lbs/ft², e.g., in some embodiments the nominal density can be about 1.29 lbs/ft³ and the nominal weight can be about 0.1075 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 1.3 lbs/ft³ and a nominal weight of about 0.1 lbs/ft², e.g., in some embodiments the nominal density can be about 1.34 lbs/ft³ and the nominal weight can be about 0.1117 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 1.4 lbs/ft³ and a nominal weight of about 0.1 lbs/ft², e.g., in some embodiments the nominal density can be about 1.38 lbs/ft³ and the nominal weight can be about 0.1153 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 1.4 lbs/ft³ and a nominal weight of about 0.1 lbs/ft², e.g., in some embodiments the nominal density can be about 1.41 lbs/ft³ and the nominal weight can be about 0.1175 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 1.4 lbs/ft³ and a nominal weight of about 0.1 lbs/ft², e.g., in some embodiments the nominal density can be about 1.44 lbs/ft³ and the nominal weight can be about 0.1200 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 1.5 lbs/ft³ and a nominal weight of about 0.1 lbs/ft², e.g., in some embodiments the nominal density can be about 1.53 lbs/ft³ and the nominal weight can be about 0.1275 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 1.6 lbs/ft³ and a nominal weight of about 0.1 lbs/ft², e.g., in some embodiments the nominal density can be about 1.57 lbs/ft³ and the nominal weight can be about 0.1311 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 1.6 lbs/ft³ and a nominal weight of about 0.1 lbs/ft², e.g., in some embodiments the nominal density can be about 1.63 lbs/ft³ and the nominal weight can be about 0.1360 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 1.7 lbs/ft³ and a nominal weight of about 0.1 lbs/ft², e.g., in some embodiments the nominal density can be about 1.73 lbs/ft³ and the nominal weight can be about 0.1444 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 1.8 lbs/ft³ and a nominal weight of about 0.1 lbs/ft², e.g., in some embodiments the nominal density can be about 1.78 lbs/ft³ and the nominal weight can be about 0.1487 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 1.8 lbs/ft³ and a nominal weight of about 0.1 lbs/ft², e.g., in some embodiments the nominal density can be about 1.84 lbs/ft³ and the nominal weight can be about 0.1530 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 1.9 lbs/ft³ and a nominal weight of about 0.1 lbs/ft², e.g., in some embodiments the nominal density can be about 1.89 lbs/ft³ and the nominal weight can be about 0.1572 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 1.9 lbs/ft³ and a nominal weight of about 0.2 lbs/ft², e.g., in some embodiments the nominal density can be about 1.94 lbs/ft³ and the nominal weight can be about 0.1615 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 2.0 lbs/ft³ and a nominal weight of about 0.2 lbs/ft², e.g., in some embodiments the nominal density can be about 2.04 lbs/ft³ and the nominal weight can be about 0.1700 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 2.1 lbs/ft³ and a nominal weight of about 0.2 lbs/ft², e.g., in some embodiments the nominal density can be about 2.14 lbs/ft³ and the nominal weight can be about 0.1780 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 2.2 lbs/ft³ and a nominal weight of about 0.2 lbs/ft², e.g., in some embodiments the nominal density can be about 2.24 lbs/ft³ and the nominal weight can be about 0.1870 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 2.3 lbs/ft³ and a nominal weight of about 0.2 lbs/ft², e.g., in some embodiments the nominal density can be about 2.25 lbs/ft³ and the nominal weight can be about 0.1875 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 2.5 lbs/ft³ and a nominal weight of about 0.2 lbs/ft², e.g., in some embodiments the nominal density can be about 2.50 lbs/ft³ and the nominal weight can be about 0.2083 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 2.6 lbs/ft³ and a nominal weight of about 0.2 lbs/ft², e.g., in some embodiments the nominal density can be about 2.65 lbs/ft³ and the nominal weight can be about 0.2208 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 2.8 lbs/ft³ and a nominal weight of about 0.2 lbs/ft², e.g., in some embodiments the nominal density can be about 2.75 lbs/ft³ and the nominal weight can be about 0.2292 lbs/ft². In another variation, “ship out” uncured has a nominal density of about 3.0 lbs/ft³ and a nominal weight of about 0.3 lbs/ft², e.g., in some embodiments the nominal weight can be about 0.2500 lbs/ft².

In another illustrative embodiment, the uncured binders described herein can be used as glass fiber binders in uncured fiberglass insulation products exemplified by pipe insulation-uncured. Pipe insulation-uncured is manufactured as a rolled-up blanket including glass fibers that are loosely bonded together with a thermosetting binder. This insulation is typically an in-process material, which is shipped in a wet and uncured state to be further processed by heat curing into varying densities and dimensions of cured pipe insulation, which insulation has specific thermal performance requirements (see cured pipe insulation embodiment below). Thickness and/or density are determined in accordance with ASTM C 167. Pipe insulation-uncured typically requires a nominal moisture content of about 3+about 2.0%/−about 1.0%, a nominal binder content of about 7±about 2.0%, and a nominal fiber diameter of about 30±about 4 ht.

In one illustrative variation, pipe insulation-uncured has a nominal density of about 0.8 lbs/ft³ and a nominal weight of about 0.07 lbs/ft², e.g., in some embodiments the nominal density can be about 0.85 lbs/ft³ and the nominal weight can be about 0.0708 lbs/ft². In another variation, pipe insulation-uncured has a nominal density of about 0.8 lbs/ft³ and a nominal weight of about 0.07 lbs/ft², e.g., in some embodiments the nominal density can be about 0.85 lbs/ft³ and the nominal weight can be about 0.0736 lbs/ft².

In another illustrative embodiment, the uncured binders described herein can be used as glass fiber binders in uncured fiberglass insulation products exemplified by filter tube insulation-uncured. Filter tube insulation-uncured is manufactured as a rolled-up blanket including glass fibers that are loosely bonded together with a thermosetting binder. This insulation is typically an in-process material, which is shipped in a wet and uncured state to be further processed by heat curing into varying densities and dimensions of cured filter tube insulation, which insulation has specific thermal performance requirements (see cured pipe insulation embodiment below). Thickness and/or density are determined in accordance with ASTM C 167. Filter tube insulation-uncured insulation typically requires a nominal moisture content of about 3+about 2.0/−about 1.0%, a nominal binder content of about 10±about 1.0%, and a nominal fiber diameter of about 27±about 4 ht.

In one illustrative variation, filter tube insulation-uncured has a nominal density of about 0.8 lbs/ft³ and a nominal weight of about 0.07 lbs/ft², e.g., in some embodiments the nominal density can be about 0.85 lbs/ft³ and the nominal weight can be about 0.0708 lbs/ft². In another variation, filter tube insulation-uncured has a nominal density of about 0.8 lbs/ft³ and a nominal weight of about 0.07 lbs/ft², e.g., in some embodiments the nominal density can be about 0.85 lbs/ft³ and the nominal weight can be about 0.0736 lbs/ft².

It should be understood that the aqueous binders described herein can be cured, and that drying and curing may occur either sequentially, contemporaneously, or concurrently. For example, any of the above-described aqueous binders can be disposed (e.g., sprayed) on the material to be bound, and then heated. Illustratively, in the case of making fiberglass insulation products, after the aqueous binder has been applied to the mat, the binder-coated mat is immediately or eventually transferred to a curing oven (eventual transfer is typical when additional components, such as various types of oversprays and porous glass fiber facings, for example, are added to the binder-coated mat prior to curing). In the curing oven the mat is heated (e.g., from about 300° F. to about 600° F.) and the binder is cured. The cured binder is a formaldehyde-free, water-resistant thermoset binder that attaches the glass fibers of the mat together. The mat of fiberglass may be processed to form one of several types of fiberglass materials, such as fiberglass insulation products.

It should be appreciated that materials including a collection of glass fibers bonded with the binders of the present invention may have a density in the range from about 0.4 lbs/ft³ to about 6 lbs/ft³. It should also be appreciated that such materials may have an R-value in the range from about 2 to about 60. Further, it should be appreciated that such materials may have a noise reduction coefficient in the range from about 0.45 to about 1.10.

In one illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by acoustical board insulation. Acoustical board insulation is a thermal and acoustical insulation product including glass fibers that are preformed into boards and bonded with a thermoset binder. This product may be manufactured plain, or faced with white mat, factory-applied foil-scrim-kraft (FSK), white poly-scim-kraft (PSK), or all-service-jacket (ASJ) facings. Acoustical board insulation may be used in ceiling panels, wall treatments, sound baffles, office dividers, and other applications where thermal and/or acoustical efficiency is required. Thermal conductivity and acoustical properties for acoustical board insulation are determined in accordance with ASTM C177 and ASTM C423 (Type A Mounting), respectively. Thickness and/or density are determined in accordance with ASTM C 167. Acoustical board insulation typically requires a nominal fiber diameter of about 20±about 3 ht for less than about 3 lb/ft³ density board, and about 27±about 3 ht for greater than or equal to 3 lbs/ft³ density board, and nominal loss on ignition of about 11±about 2%.

In one illustrative variation, acoustical board insulation has a density of about 2 lbs/ft³, a nominal thickness of about 1 in, 1.5 in, 2 in, 2.5 in, 3 in, 3.5 in, and 4 in, and a thermal conductivity of about 0.24 BTU in/hr ft²° F. at 75° F., about 0.25 BTU in/hr ft²° F. at 100° F., about 0.33 BTU in/hr ft²° F. at 200° F., and about 0.42 BTU in/hr ft²° F. at 300° F., e.g., in such embodiments the density can be about 1.6 lbs/ft³. In another variation, acoustical board insulation has a density of about 2 lbs/ft³, a nominal thickness of about 1 in, 1.5 in, 2 in, 2.5 in, 3 in, 3.5 in, and 4 in, and a noise reduction coefficient of about 0.65 at 1-in thickness, about 0.85 at 1.5-in thickness, and about 0.95 at 2-in thickness, e.g., in such embodiments the density can be about 2.25 lbs/ft³. In another variation, acoustical board insulation has a density of about 3 lbs/ft³, a nominal thickness of about 1 in, 1.5 in, 2 in, 2.5 in, 3 in, 3.5 in, and 4 in, a thermal conductivity of about 0.23 BTU in/hr ft²° F. at 75° F., about 0.24 BTU in/hr ft²° F. at 100° F., about 0.29 BTU in/hr ft²° F. at 200° F., about 0.37 BTU in/hr ft²° F. at 300° F., and a noise reduction coefficient of about 0.65 at 1-in thickness, about 0.85 at 1.5-in thickness, and about 1.00 at 2-in thickness. In another variation, acoustical board insulation has a density of about 4 lbs/ft³, a nominal thickness of about 1 in, 1.5 in, 2 in, and 2.5 in, and a noise reduction coefficient of about 0.75 at 1-in thickness, e.g., in such embodiments the density can be about 4.25 lbs/ft³. In another variation, acoustical board insulation has a density of about 6 lbs/ft³, a nominal thickness of about 1 in, 1.5 in, and 2 in, a thermal conductivity of about 0.22 BTU in/hr ft²° F. at 75° F., about 0.23 BTU in/hr ft²° F. at 100° F., about 0.27 BTU in/hr ft²° F. at 200° F., about 0.34 BTU in/hr ft²° F. at 300° F., and a noise reduction coefficient of about 0.80 at 1-in thickness, about 0.90 at 1.5-in thickness, and about 1.00 at 2-in thickness.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by acoustical board-black. Acoustical board-black is an acoustical insulation product including glass fibers that are preformed into boards and bonded with a thermoset binder. This product has a black overspray applied to provide a tough finish with a dark surface. Acoustical board-black may be used on walls and ceilings when reduction of airborne sound transmission is desired, where system design requires a rigid product, and where additional strength and abuse resistance are required. Acoustical properties for acoustical board-black are determined in accordance with ASTM C423 (Type A Mounting). Thickness and/or density are determined in accordance with ASTM C 167. Acoustical board-black typically requires a nominal fiber diameter of about 33±about 2 ht, and an overspray of black dye applied to the top of the product.

In one illustrative variation, acoustical board-black has a density of about 2 lbs/ft³, a nominal thickness of about 1.5 in and 2 in, and a noise reduction coefficient of about 0.95 at 2-in thickness, e.g., in such embodiments the density can be about 2.25 lbs/ft³. In another variation, acoustical board-black has a density of about 3 lbs/ft³, a nominal thickness of about 1 in, 1.5 in, 2 in, and 3 in, and a noise reduction coefficient of about 0.65 at 1-in thickness, about 0.85 at 1.5-in thickness, and about 0.95 at 2-in thickness. In another variation, acoustical board-black has a density of about 4 lbs/ft³, a nominal thickness of about 1 in, 1.5 in, 2 in, and 3 in, and a square foot weight of about 0.3 lbs/ft², about 0.5 lbs/ft², about 0.7 lbs/ft², and about 1.0 lbs/ft², respectively, e.g., in such embodiments the density can be about 4.25 lbs/ft³ and the square foot weight can be 0.3542 lbs/ft², 0.5313 lbs/ft², 0.7083 lbs/ft², and 1.0625 lbs/ft², respectively.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by acoustical board-smooth. Acoustical board-smooth is a thermal and acoustical insulation product including glass fibers that are preformed into boards and bonded with a thermoset binder. Acoustical board-smooth is smooth on one side with precision-cut tolerances. Products with a density ranging from about 3 lbs/ft³ to about 6 lbs/ft³, and a thickness of about 1 in or greater have a smooth surface made from the manufacturing process. Products less than about 1-in thick are bisected. Acoustical board-smooth may be used in thermal and acoustical applications such as office partitions, interior panels, and sound baffles. Thermal conductivity and acoustical properties for acoustical board-smooth are determined in accordance with ASTM C518 (75° F. mean temperature) and ASTM C423 (Type A Mounting), respectively. Thickness and/or density are determined in accordance with ASTM C 167. Acoustical board-smooth typically requires a nominal fiber diameter of about 34±about 3 ht, and nominal loss on ignition of about 17±about 2%.

In one illustrative variation, acoustical board-smooth has a density of about 3 lbs/ft³, a nominal thickness of about 1 in, 1.5 in, 2 in, and 3 in, a thermal conductivity of about 0.23 BTU in/hr ft²° F. at 75° F., and a noise reduction coefficient of about 0.65 at 1-in thickness, about 0.85 at 1.5-in thickness, about 1.00 at 2-in thickness, and about 1.10 at 3-in thickness. In another variation, acoustical board-smooth has a density of about 4 lbs/ft³, a nominal thickness of about 0.5 in, 1 in, 1.5 in, and 2 in, a thermal conductivity of about 0.23 BTU in/hr ft²° F. at 75° F., and a noise reduction coefficient of about 0.75 at 1-in thickness, e.g., in such embodiments the density can be about 4.25 lbs/ft³. In another variation, acoustical board-smooth has a density of about 6 lbs/ft³, a nominal thickness of about 0.5 in, 1 in, 1.5 in, and 2 in, a thermal conductivity of about 0.22 BTU in/hr ft²° F. at 75° F., and a noise reduction coefficient of about 0.80 at 1-in thickness, about 0.90 at 1.5-in thickness, and about 1.00 at 2-in thickness.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by cured blanket insulation, which product may be referred to as “amber blanket” when binders other than those of the present invention are used. Cured blanket insulation is a uniformly textured, resilient, thermal insulating and sound absorbing material including glass fibers bonded with a thermoset binder. This product has sufficient tensile strength to allow for die-cutting, fabrication, lamination, and installation in OEM applications. Cured blanket insulation may be used as thermal and/or acoustical insulation for appliance, equipment, industrial, commercial, and marine applications up to about 650° F. Thermal conductivity and acoustical properties for cured blanket insulation are determined in accordance with ASTM C518 (75° F. mean temperature) and ASTM C423 (Type A Mounting), respectively. Thickness and/or density are determined in accordance with ASTM C 167. Cured blanket insulation typically requires a nominal fiber diameter of about 20±about 2 ht or about 22±about 2 ht, and nominal loss on ignition of about 10±about 1%.

In one illustrative variation, cured blanket insulation has a density of about 0.8 lbs/ft³, a nominal thickness of about 1 in, 1.5 in, and 2 in, a thermal conductivity of about 0.30 BTU in/hr ft²° F. at 75° F., and a noise reduction coefficient of about 0.70 at 1.5-in thickness, e.g., in such embodiments the density can be about 0.75 lbs/ft³. In another variation, cured blanket insulation has a density of about 1 lbs/ft³, a nominal thickness of about 1 in, 1.5 in, and 2 in, a thermal conductivity of about 0.28 BTU in/hr ft²° F. at 75° F., and a noise reduction coefficient of about 0.65 at 1-in thickness. In another variation, cured blanket insulation has a density of about 1 lbs/ft³, a nominal thickness of about 0.5 in, 0.75 in, 1 in, and 1.5 in, a thermal conductivity of about 0.26 BTU in/hr ft²° F. at 75° F., and a noise reduction coefficient of about 0.60 at 0.5-in thickness, e.g., in such embodiments the density can be about 1.5 lbs/ft³. In another variation, cured blanket insulation has a density of about 2 lbs/ft³, a nominal thickness of about 0.5 in, 0.75 in, and 1 in, a thermal conductivity of about 0.24 BTU in/hr ft²° F. at 75° F., and a noise reduction coefficient of about 0.65 at 0.75-in thickness. In another variation, cured blanket insulation has a density of about 2.5 lbs/ft³, a nominal thickness of about 0.5 in, a thermal conductivity of about 0.23 BTU in/hr ft²° F. at 75° F., and a noise reduction coefficient of about 0.60 at 0.5-in thickness.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by black diffuser board. Black diffuser board is a thermal and acoustical insulation product including glass fibers that are preformed into heavy density boards and bonded with a thermoset binder. The product can be bottom-faced with foil-scrim-kraft (FSK) facing, and it has a black overspray applied to the air stream surface to provide a tough finish with a dark surface. Black diffuser board may be used as an interior insulation material for heating, ventilating, and air conditioning diffusers as well as other air distribution components. It offers a combination of sound absorption, low thermal conductivity, and minimal air surface friction for systems operating at temperatures up to about 250° F. and velocities up to about 5,000 fpm. Thermal properties and acoustical properties for black diffuser board are determined in accordance with ASTM C177 (75° F. mean temperature) and ASTM C423 (Type A Mounting), respectively. Thickness and/or density are determined in accordance with ASTM C 167. Black diffuser board typically requires a nominal fiber diameter of about 33±about 2 ht, a nominal loss on ignition of about 13± about 2%, and an overspray of black dye applied to the top of the product.

In one illustrative variation, black diffuser board has a density of about 3 lbs/ft³, a nominal thickness of about 1 in, 1.4 in, 1.9 in, and 2 in, a thermal conductivity of about 0.23 BTU in/hr ft²° F. at 1-in thickness, about 0.15 BTU in/hr ft²° F. at 1.5-in thickness, about 0.11 BTU in/hr ft²° F. at 2-in thickness, and a noise reduction coefficient of about 0.65 at 1-in thickness, about 0.85 at 1.5-in thickness, and about 0.95 at 2-in thickness. In another variation, black diffuser board has a density of about 4 lbs/ft³, a nominal thickness of about 1 in and 1.4 in, and a square foot weight of about 0.3 lbs/ft² and 0.4 lbs/ft², respectively, e.g., in such embodiments the square foot weight can be about 0.3333 lbs/ft² and 0.4583 lbs/ft², respectively.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by SUMMIT loose-fill blowing insulation. SUMMIT loose-fill blowing insulation typically includes unbonded fiberglass with a nominal fiber diameter and nominal fiber length, however, such fiberglass may be bonded with the cured thermoset binders described herein and subsequently cut apart (shredded) in, for example, a hammer mill, to be used in loose-fill blowing insulation. SUMMIT loose-fill blowing insulation may be used for loose-fill thermal insulation applications in attics, sidewalls, and floors, and is applied with a pneumatic blowing machine. The product is typically sprayed with silicone, dedusting oil, and anti-static agents in order to improve blowing properties and performance. Thermal resistance properties for SUMMIT loose-fill blowing insulation are determined in accordance with ASTM C687 using ASTM C518. SUMMIT loose-fill blowing insulation typically requires a nominal average fiber diameter of about 9±about 1.5 ht, a nominal fiber length of about 0.75±about 0.25 in, nominal loss on ignition of about 1.5±about 0.5%, and a nominal density of about 0.5 lbs/ft³.

In one illustrative variation, SUMMIT loose-fill blowing insulation with an R-value of about 60 requires an installed minimum square foot weight of about 1 lbs/ft² and an installed minimum thickness of about 23.5 in. In another variation, SUMMIT loose-fill blowing insulation with an R-value of about 49 requires an installed minimum square foot weight of about 0.8 lbs/ft² and an installed minimum thickness of about 19.5 in. In another variation, SUMMIT loose-fill blowing insulation with an R-value of about 44 requires an installed minimum square foot weight of about 0.7 lbs/ft² and an installed minimum thickness of about 17.7 in. In another variation, SUMMIT loose-fill blowing insulation with an R-value of about 38 requires an installed minimum square foot weight of about 0.6 lbs/ft² and an installed minimum thickness of about 15.5 in. In another variation, SUMMIT loose-fill blowing insulation with an R-value of about 30 requires an installed minimum square foot weight of about 0.5 lbs/ft² and an installed minimum thickness of about 12.5 in. In another variation, SUMMIT loose-fill blowing insulation with an R-value of about 26 requires an installed minimum square foot weight of about 0.4 lbs/ft² and an installed minimum thickness of about 11 in. In another variation, SUMMIT loose-fill blowing insulation with an R-value of about 22 requires an installed minimum square foot weight of about 0.3 lbs/ft² and an installed minimum thickness of about 9.3 in. In another variation, SUMMIT loose-fill blowing insulation with an R-value of about 19 requires an installed minimum square foot weight of about 0.3 lbs/ft² and an installed minimum thickness of about 8 in. In another variation, SUMMIT loose-fill blowing insulation with an R-value of about 13 requires an installed minimum square foot weight of about 0.2 lbs/ft² and an installed minimum thickness of about 5.8 in. In another variation, SUMMIT loose-fill blowing insulation with an R-value of about 11 requires an installed minimum square foot weight of about 0.2 lbs/ft² and an installed minimum thickness of about 4.8 in.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by JET STREAM loose-fill blowing insulation. JET STREAM loose-fill blowing insulation typically includes unbonded fiberglass with a nominal fiber diameter and nominal fiber length, however, such fiberglass may be bonded with the cured thermoset binders described herein and subsequently cut apart (shredded) in, for example, a hammer mill, to be used in loose-fill blowing insulation. JET STREAM loose-fill blowing insulation may be used for loose-fill thermal insulation applications in attics, sidewalls, and floors, and is applied with a pneumatic blowing machine. The product is typically sprayed with silicone, dedusting oil, and anti-static agents in order to improve blowing properties and performance. Thermal resistance properties for JET STREAM loose-fill blowing insulation are determined in accordance with ASTM C687 using ASTM C518. JET STREAM loose-fill blowing insulation typically requires a nominal average fiber diameter of about 7.5±about 1.5 ht, a nominal fiber length of about 0.75±about 0.25 in, nominal loss on ignition of about 1.25±about 0.4%, and a nominal density of about 0.5 lbs/ft³.

In one illustrative variation, JET STREAM loose-fill blowing insulation with an R-value of about 60 requires an installed minimum square foot weight of about 1 lbs/ft² and an installed minimum thickness of about 19.7 in. In another variation, JET STREAM loose-fill blowing insulation with an R-value of about 49 requires an installed minimum square foot weight of about 0.8 lbs/ft² and an installed minimum thickness of about 16.5 in. In another variation, JET STREAM loose-fill blowing insulation with an R-value of about 44 requires an installed minimum square foot weight of about 0.7 lbs/ft² and an installed minimum thickness of about 14.8 in. In another variation, JET STREAM loose-fill blowing insulation with an R-value of about 38 requires an installed minimum square foot weight of about 0.6 lbs/ft² and an installed minimum thickness of about 13 in. In another variation, JET STREAM loose-fill blowing insulation with an R-value of about 30 requires an installed minimum square foot weight of about 0.4 lbs/ft² and an installed minimum thickness of about 10.2 in. In another variation, JET STREAM loose-fill blowing insulation with an R-value of about 26 requires an installed minimum square foot weight of about 0.4 lbs/ft² and an installed minimum thickness of about 9 in. In another variation, JET STREAM loose-fill blowing insulation with an R-value of about 22 requires an installed minimum square foot weight of about 0.3 lbs/ft² and an installed minimum thickness of about 7.8 in. In another variation, JET STREAM loose-fill blowing insulation with an R-value of about 19 requires an installed minimum square foot weight of about 0.3 lbs/ft² and an installed minimum thickness of about 6.8 in. In another variation, JET STREAM loose-fill blowing insulation with an R-value of about 13 requires an installed minimum square foot weight of about 0.2 lbs/ft² and an installed minimum thickness of about 4.8 in. In another variation, JET STREAM loose-fill blowing insulation with an R-value of about 11 requires an installed minimum square foot weight of about 0.1 lbs/ft² and an installed minimum thickness of about 4 in.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by Medium-density loose-fill blowing (blue-label) insulation. Medium-density loose-fill blowing insulation includes off-grade fiberglass batts and rolls that have been shredded (e.g., in a hammer mill) into small nodules. It is not composed of uncured, undercured, or overcured material, or material with density greater than about 1 lb/ft³. Medium-density loose-fill blowing insulation may be used for loose-fill thermal insulation applications in attics, sidewalls, and floors, and is applied with a pneumatic blowing machine. Thermal resistance properties for Medium-density loose-fill blowing insulation are determined in accordance with ASTM C687 using ASTM C518. Medium-density loose-fill blowing insulation typically requires golf ball-size nodules and a nominal density of about 0.6 lbs/ft³.

In one illustrative variation, Medium-density loose-fill blowing insulation with an R-value of about 60 requires an installed minimum square foot weight of about 1.4 lbs/ft² and an installed minimum thickness of about 23.5 in, e.g., in such embodiments the installed minimum square foot weight can be about 1.447 lbs/ft². In another variation, Medium-density loose-fill blowing insulation with an R-value of about 49 requires an installed minimum square foot weight of about 1.2 lbs/ft² and an installed minimum thickness of about 20.2 in, e.g., in such embodiments the installed minimum square foot weight can be about 1.190 lbs/ft². In another variation, Medium-density loose-fill blowing insulation with an R-value of about 44 requires an installed minimum square foot weight of about 1.0 lbs/ft² and an installed minimum thickness of about 18 in, e.g., in such embodiments the installed minimum square foot weight can be about 1.022 lbs/ft². In another variation, Medium-density loose-fill blowing insulation with an R-value of about 38 requires an installed minimum square foot weight of about 0.9 lbs/ft² and an installed minimum thickness of about 16 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.881 lbs/ft². In another variation, Medium-density loose-fill blowing insulation with an R-value of about 30 requires an installed minimum square foot weight of about 0.7 lbs/ft² and an installed minimum thickness of about 13 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.682 lbs/ft². In another variation, Medium-density loose-fill blowing insulation with an R-value of about 26 requires an installed minimum square foot weight of about 0.6 lbs/ft² and an installed minimum thickness of about 11.2 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.573 lbs/ft². In another variation, Medium-density loose-fill blowing insulation with an R-value of about 22 requires an installed minimum square foot weight of about 0.5 lbs/ft² and an installed minimum thickness of about 9.7 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.484 lbs/ft². In another variation, Medium-density loose-fill blowing insulation with an R-value of about 19 requires an installed minimum square foot weight of about 0.4 lbs/ft² and an installed minimum thickness of about 8.5 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.413 lbs/ft². In another variation, Medium-density loose-fill blowing insulation with an R-value of about 13 requires an installed minimum square foot weight of about 0.3 lbs/ft² and an installed minimum thickness of about 6 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.279 lbs/ft². In another variation, Medium-density loose-fill blowing insulation with an R-value of about 11 requires an installed minimum square foot weight of about 0.2 lbs/ft² and an installed minimum thickness of about 5.2 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.240 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by Low-density loose-fill blowing (orange-label) insulation. Low-density loose-fill blowing insulation includes off-grade fiberglass batts and rolls of residential insulation that have been shredded (e.g., in a hammer mill) into small nodules. It is not composed of uncured, undercured, or overcured material, or material with density greater than about 1 lb/ft³. Low-density loose-fill blowing insulation may be used for loose-fill thermal insulation applications in attics, sidewalls, and floors, and is applied with a pneumatic blowing machine. Thermal resistance properties for Low-density loose-fill blowing insulation are determined in accordance with ASTM C687 using ASTM C518. Low-density loose-fill blowing insulation typically requires golf ball-size nodules and a nominal density of about 0.5 lbs/ft³.

In one illustrative variation, Low-density loose-fill blowing insulation with an R-value of about 60 requires an installed minimum square foot weight of about 1.3 lbs/ft² and an installed minimum thickness of about 27.5 in, e.g., in such embodiments the installed minimum square foot weight can be about 1.311 lbs/ft². In another variation, Low-density loose-fill blowing insulation with an R-value of about 49 requires an installed minimum square foot weight of about 1.0 lbs/ft² and an installed minimum thickness of about 23 in, e.g., in such embodiments the installed minimum square foot weight can be about 1.046 lbs/ft². In another variation, Low-density loose-fill blowing insulation with an R-value of about 44 requires an installed minimum square foot weight of about 0.9 lbs/ft² and an installed minimum thickness of about 21 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.935 lbs/ft². In another variation, Low-density loose-fill blowing insulation with an R-value of about 38 requires an installed minimum square foot weight of about 0.8 lbs/ft² and an installed minimum thickness of about 18.5 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.801 lbs/ft². In another variation, Low-density loose-fill blowing insulation with an R-value of about 30 requires an installed minimum square foot weight of about 0.6 lbs/ft² and an installed minimum thickness of about 15 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.624 lbs/ft². In another variation, Low-density loose-fill blowing insulation with an R-value of about 26 requires an installed minimum square foot weight of about 0.5 lbs/ft² and an installed minimum thickness of about 13 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.528 lbs/ft². In another variation, Low-density loose-fill blowing insulation with an R-value of about 22 requires an installed minimum square foot weight of about 0.4 lbs/ft² and an installed minimum thickness of about 11.2 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.447 lbs/ft². In another variation, Low-density loose-fill blowing insulation with an R-value of about 19 requires an installed minimum square foot weight of about 0.4 lbs/ft² and an installed minimum thickness of about 10 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.392 lbs/ft². In another variation, Low-density loose-fill blowing insulation with an R-value of about 13 requires an installed minimum square foot weight of about 0.3 lbs/ft² and an installed minimum thickness of about 7 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.264 lbs/ft². In another variation, Low-density loose-fill blowing insulation with an R-value of about 11 requires an installed minimum square foot weight of about 0.2 lbs/ft² and an installed minimum thickness of about 6 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.223 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by High-density loose-fill blowing (purple-label) insulation. High-density loose-fill blowing insulation includes off-grade fiberglass batts, blankets, and rolls (produced from large, high-strength fibers) that have been shredded (e.g., in a hammer mill) into small nodules. It is not composed of uncured, undercured, or overcured material, or material with density greater than about 1 lb/ft³. High-density loose-fill blowing insulation may be used for loose-fill thermal insulation applications in attics, sidewalls, and floors, and is applied with a pneumatic blowing machine. Thermal resistance properties for High-density loose-fill blowing insulation are determined in accordance with ASTM C687 using ASTM C518. High-density loose-fill blowing insulation typically requires golf ball-size nodules and a nominal density of about 0.7 lbs/ft³.

In one illustrative variation, High-density loose-fill blowing insulation with an R-value of about 60 requires an installed minimum square foot weight of about 1.6 lbs/ft² and an installed minimum thickness of about 24 in, e.g., in such embodiments the installed minimum square foot weight can be about 1.647 lbs/ft². In another variation, High-density loose-fill blowing insulation with an R-value of about 49 requires an installed minimum square foot weight of about 1.3 lbs/ft² and an installed minimum thickness of about 20 in, e.g., in such embodiments the installed minimum square foot weight can be about 1.322 lbs/ft². In another variation, High-density loose-fill blowing insulation with an R-value of about 44 requires an installed minimum square foot weight of about 1.2 lbs/ft² and an installed minimum thickness of about 18.2 in, e.g., in such embodiments the installed minimum square foot weight can be about 1.186 lbs/ft². In another variation, High-density loose-fill blowing insulation with an R-value of about 38 requires an installed minimum square foot weight of about 1.0 lbs/ft² and an installed minimum thickness of about 16 in, e.g., in such embodiments the installed minimum square foot weight can be about 1.017 lbs/ft². In another variation, High-density loose-fill blowing insulation with an R-value of about 30 requires an installed minimum square foot weight of about 0.8 lbs/ft² and an installed minimum thickness of about 12.7 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.784 lbs/ft². In another variation, High-density loose-fill blowing insulation with an R-value of about 26 requires an installed minimum square foot weight of about 0.7 lbs/ft² and an installed minimum thickness of about 11.2 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.681 lbs/ft². In another variation, High-density loose-fill blowing insulation with an R-value of about 22 requires an installed minimum square foot weight of about 0.6 lbs/ft² and an installed minimum thickness of about 9.5 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.565 lbs/ft². In another variation, High-density loose-fill blowing insulation with an R-value of about 19 requires an installed minimum square foot weight of about 0.5 lbs/ft² and an installed minimum thickness of about 8.2 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.484 lbs/ft². In another variation, High-density loose-fill blowing insulation with an R-value of about 13 requires an installed minimum square foot weight of about 0.3 lbs/ft² and an installed minimum thickness of about 5.7 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.328 lbs/ft². In another variation, High-density loose-fill blowing insulation with an R-value of about 11 requires an installed minimum square foot weight of about 0.3 lbs/ft² and an installed minimum thickness of about 5 in, e.g., in such embodiments the installed minimum square foot weight can be about 0.283 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by PERIMETER PLUS loose-fill blowing insulation. PERIMETER PLUS loose-fill blowing insulation typically includes unbonded fiberglass with a nominal fiber diameter and nominal fiber length, however, such fiberglass may be bonded with the cured thermoset binders described herein and subsequently cut apart (shredded) in, for example, a hammer mill, to be used in loose-fill blowing insulation. PERIMETER PLUS loose-fill blowing insulation may be used for loose-fill thermal insulation applications in the sidewalls and/or other closed cavities of framed buildings where ventilation is not required, and is applied with a pneumatic blowing machine. The product is typically sprayed with silicone, dedusting oil, and anti-static agents in order to improve blowing properties and performance, and is installed behind approved netting. Thermal resistance properties for PERIMETER PLUS loose-fill blowing insulation are determined in accordance with ASTM C687 using ASTM C518. PERIMETER PLUS loose-fill blowing insulation typically requires a nominal average fiber diameter of about 7.5± about 1.5 ht, a nominal fiber length of about 0.5+about 0.5 in/− 0 in, nominal loss on ignition of about 1.25±about 0.4%, and a nominal density of about 0.5 lbs/ft³.

In one illustrative variation, PERIMETER PLUS loose-fill blowing insulation installed in a cavity depth of about 3.5 in (2×4 framing) at a density of about 2 lbs/ft³, and a minimum weight per square foot of about 0.5 lbs/ft², achieves an R-value of about 15. In another variation, PERIMETER PLUS loose-fill blowing insulation installed in a cavity depth of about 5.5 in (2×6 framing) at a density of about 2 lbs/ft³, and a minimum weight per square foot of about 0.8 lbs/ft², achieves an R-value of about 23. In another variation, PERIMETER PLUS loose-fill blowing insulation installed in a cavity depth of about 7.2 in (2×8 framing) at a density of about 2 lbs/ft³, and a minimum weight per square foot of about 1.1 lbs/ft², achieves an R-value of about 31. In another variation, PERIMETER PLUS loose-fill blowing insulation installed in a cavity depth of about 9.2 in (2×10 framing) at a density of about 2 lbs/ft³, and a minimum weight per square foot of about 1.4 lbs/ft² achieves an R-value of about 39.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by air duct board. Air duct board is a thermal and acoustical insulation product including glass fibers preformed into rigid, rectangular boards bonded with a thermoset binder. Air duct board is faced on the bottom with a foil-scrim-kraft (FSK) facing, and the air stream surface is faced with a lightweight black mat. The mat facing is intended to improve the abuse resistance of the airstream surface, lower the resistance to air flow, and improve the aesthetic appearance. Air duct board may be used in commercial and residential air handling installations, for cooling, heating, or dual-temperature service at operating temperatures ranging up to about 250° F., maximum air velocities of about 5000 fpm and about 2-in static pressure. Thermal resistance and acoustical properties for air duct board are determined in accordance with ASTM C518/ASTM C177 (at 75° F.) and ASTM E477, respectively. Thickness and/or density are determined in accordance with ASTM C 167. Air duct board typically requires a nominal fiber diameter of about 32±about 2 ht, nominal loss on ignition of about 15±about 2%, and application of a black overspray prior to thermal curing to adhere the non-woven mat to the board.

In one illustrative variation, air duct board has a nominal thickness of about 1 in, a flexural rigidity of about 475, and R-value of about 4.3, a density of about 4.5 lbs/ft³, a thermal conductivity of about 0.23 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.70. In another illustrative variation, air duct board has a nominal thickness of about 1.5 in, a flexural rigidity of about 800, and R-value of about 6.5, a density of about 3.8 lbs/ft³, a thermal conductivity of about 0.23 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.95, e.g., in such embodiments the density can be about 3.75 lbs/ft³. In another illustrative variation, air duct board has a nominal thickness of about 2 in, a flexural rigidity of about 800, and R-value of about 8.7, a density of about 3.8 lbs/ft³, and a thermal conductivity of about 0.23 BTU in/hr ft²° F., e.g., in such embodiments the density can be about 3.75 lbs/ft³.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by air duct board (all glass mat). Air duct board (all glass mat) is a thermal and acoustical insulation product including glass fibers preformed into rigid, rectangular boards bonded with a thermoset binder. Air duct board (all glass mat) is faced on the bottom with a foil-scrim-kraft (FSK) facing, and the air stream surface is faced with a lightweight white glass mat. The mat facing is intended to improve the abuse resistance of the airstream surface, lower the resistance to air flow, and improve the aesthetic appearance. Air duct board (all glass mat) may be used in commercial and residential air handling installations, for cooling, heating, or dual-temperature service at operating temperatures ranging up to about 250° F., maximum air velocities of about 5000 fpm and about 2-in static pressure. Thermal resistance and acoustical properties for air duct board (all glass mat) are determined in accordance with ASTM C518/ASTM C177 (at 75° F.) and ASTM E477, respectively. Thickness and/or density are determined in accordance with ASTM C 167. Air duct board (all glass mat) typically requires a nominal fiber diameter of about 32±about 2 ht, nominal loss on ignition of about 15±about 2%, and application of a yellow overspray prior to thermal curing to adhere the non-woven mat to the board.

In one illustrative variation, air duct board (all glass mat) has a nominal thickness of about 1 in, a flexural rigidity of about 475, and R-value of about 4.3, a density of about 4.4 lbs/ft³, a thermal conductivity of about 0.23 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.70. In another variation, air duct board (all glass mat) has a nominal thickness of about 1.5 in, a flexural rigidity of about 800, and R-value of about 6.5, a density of about 4 lbs/ft³, a thermal conductivity of about 0.23 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.95, e.g., in such embodiments the density can be about 3.75 lbs/ft³. In another variation, air duct board (all glass mat) has a nominal thickness of about 2 in, a flexural rigidity of about 800, and R-value of about 8.7, a density of about 4 lbs/ft³, a thermal conductivity of about 0.23 BTU in/hr ft²° F., and a noise reduction coefficient of about 1.00, e.g., in such embodiments the density can be about 3.75 lbs/ft³.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by housing air duct board. Housing air duct board is a thermal insulation product including glass fibers preformed into rigid, rectangular boards bonded with a thermoset binder. Housing air duct board is faced on the bottom with a foil-scrim-kraft (FSK) facing, and the air stream surface is coated with an overspray prior to thermal curing to increase the abuse resistance of the airstream surface. Housing air duct board may be used in manufactured housing systems for dual-temperature service at operating temperatures ranging up to about 250° F., maximum air velocities of about 2400 fpm and about 2-in static pressure. Thermal properties for housing air duct board are determined in accordance with ASTM C518 and ASTM C177 (at 75° F.). Thickness and/or density are determined in accordance with ASTM C 167. Housing air duct board typically requires a nominal fiber diameter of about 35±about 2 ht, and a nominal loss on ignition of about 15±about 2%.

In one illustrative variation, housing air duct board has a nominal thickness of about 0.8 in, an R-value of about 3.5, a density of about 4.2 lbs/ft³, a square foot weight of about 0.3 lbs/ft², and a thermal conductivity of about 0.23 BTU in/hr ft²° F., e.g., in such embodiments the square foot weight can be about 0.2846 lbs/ft². In another variation, housing air duct board has a nominal thickness of about 1 in, an R-value of about 4.0, a density of about 4.2 lbs/ft³, a square foot weight of about 0.3 lbs/ft², and a thermal conductivity of about 0.23 BTU in/hr ft²° F., e.g., in such embodiments the square foot weight can be about 0.3281 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by duct liner. Duct liner is a flexible edge-coated, mat-faced, thermal and acoustical insulation product including glass fibers bonded with a thermoset binder. Duct liner is faced with a non-woven black mat, providing the air stream side with a smooth, abuse resistant surface during installation and operation. The side edges are coated to reduce the need for “buttering” of transverse joints during fabrication. Duct liner may be used as an interior insulation material for sheet metal ducts in heating, ventilating, and air conditioning applications. It offers a combination of sound absorption, low thermal conductivity, and minimal air surface friction characteristics for systems operating at temperatures up to about 250° F. and velocities up to about 6000 fpm. Thermal resistance and acoustical properties for duct liner are determined in accordance with ASTM C518/ASTM C177 as per ASTM C653 (at 75° F.) and ASTM C423, respectively. Thickness and/or density are determined in accordance with ASTM C 167. Duct liner typically requires a nominal fiber diameter of about 22±about 2 ht, and nominal loss on ignition of about 17±about 2%.

In one illustrative variation, duct liner has a nominal thickness of about 1 in, a nominal density of about 1.5 lbs/ft³, an R-value of about 4.2, a thermal conductivity of about 0.24 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.70. In another variation, duct liner has a nominal thickness of about 1.5 in, a nominal density of about 1.5 lbs/ft³, an R-value of about 6, a thermal conductivity of about 0.16 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.80. In another variation, duct liner has a nominal thickness of about 2 in, a nominal density of about 1.5 lbs/ft³, an R-value of about 8, a thermal conductivity of about 0.13 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.90. In another variation, duct liner has a nominal thickness of about 0.5 in, a nominal density of about 2 lbs/ft³, an R-value of about 2.1, a thermal conductivity of about 0.48 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.45. In another variation, duct liner has a nominal thickness of about 1 in, a nominal density of about 2 lbs/ft³, an R-value of about 4.2, a thermal conductivity of about 0.24 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.70. In another variation, duct liner has a nominal thickness of about 1.5 in, a nominal density of about 2 lbs/ft³, an R-value of about 6.3, a thermal conductivity of about 0.16 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.85.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by equipment liner. Equipment liner is a flexible mat-faced, thermal and acoustical insulation product including glass fibers bonded with a thermoset binder. Equipment liner is faced with a non-woven black mat, providing the air stream side with a smooth, abuse resistant surface during installation and operation. Equipment liner may be used for OEM applications in heating, ventilating, and air conditioning applications. It offers a combination of sound absorption, low thermal conductivity, and minimal air surface friction characteristics for systems operating at temperatures up to about 250° F. and velocities up to about 6000 fpm. Thermal resistance and acoustical properties for equipment liner are determined in accordance with ASTM C177 (at 75° F.) and ASTM C423 (Mounting A), respectively. Thickness and/or density are determined in accordance with ASTM C 167. Equipment liner typically requires a nominal fiber diameter of about 22±about 2 ht, and nominal loss on ignition of about 17±about 2%.

In one illustrative variation, equipment liner has a nominal thickness of about 0.5 in, a nominal density of about 1.5 lbs/ft³, a thermal conductivity of about 0.25 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.45. In another variation, equipment liner has a nominal thickness of about 1 in, a nominal density of about 1.5 lbs/ft³, a thermal conductivity of about 0.25 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.70. In another variation, equipment liner has a nominal thickness of about 1.5 in, a nominal density of about 1.5 lbs/ft³, a thermal conductivity of about 0.25 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.80. In another variation, equipment liner has a nominal thickness of about 2 in, a nominal density of about 1.5 lbs/ft³, a thermal conductivity of about 0.25 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.90. In another variation, equipment liner has a nominal thickness of about 0.5 in, a nominal density of about 2 lbs/ft³, a thermal conductivity of about 0.24 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.45. In another variation, equipment liner has a nominal thickness of about 1 in, a nominal density of about 2 lbs/ft³, a thermal conductivity of about 0.24 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.70. In another variation, equipment liner has a nominal thickness of about 1.5 in, a nominal density of about 2 lbs/ft³, a thermal conductivity of about 0.24 BTU in/hr ft²° F., and a noise reduction coefficient of about 0.85.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by duct wrap insulation. Duct wrap insulation is a uniformly textured, resilient, thermal insulating and sound absorbing material including glass fibers that are bonded with a thermoset binder. Duct wrap insulation may be used to externally insulate air handling ducts for energy conservation and condensation control. Duct wrap insulation may or may not have a facing. If faced, facings may be foil-scrim-kraft (FSK), white or black poly-scrim-kraft (PSK), or white or grey vinyl. Duct wrap insulation may be used as external insulation on commercial or residential heating or air conditioning ducts with an operating temperature of about 45° F. to about 250° F. for faced products, and on commercial or residential heating ducts with a maximum operating temperature of about 350° F. for unfaced products. Thermal resistance properties for duct wrap insulation are determined in accordance with ASTM C177 (at 75° F.) and ASTM C518. Thickness and/or density are determined in accordance with ASTM C 167. Faced duct wrap insulation typically requires a nominal fiber diameter of about 18±about 2 ht; unfaced duct wrap typically requires a nominal fiber diameter of about 20±about 2 ht (nominal loss on ignition for both is about 7±about 1%).

Illustratively, duct wrap insulation at a nominal density of about 0.75 lbs/ft³ displays thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 50° F., 0.28; 75° F., 0.29; 100° F., 0.31; 125° F., 0.33; 150° F., 0.36; 175° F., 0.39; and 200° F., 0.43. Illustratively, duct wrap insulation at a nominal density of about 1 lbs/ft³ displays thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 50° F., 0.26; 75° F., 0.27; 100° F., 0.29; 125° F., 0.31; 150° F., 0.34; 175° F., 0.37; and 200° F., 0.40. Illustratively, duct wrap insulation at a nominal density of about 1.5 lbs/ft³ displays thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 50° F., 0.23; 75° F., 0.24; 100° F., 0.26; 125° F., 0.28; 150° F., 0.31; 175° F., 0.33; and 200° F., 0.36.

In one illustrative variation, duct wrap has a nominal thickness of about 1 in, a nominal density of about 0.75 lbs/ft³, an out-of-package R-value of about 3.4, and an installed R-value (at 25% compression) of about 2.8. In another variation, duct wrap has a nominal thickness of about 1.5 in, a nominal density of about 0.75 lbs/ft³, an out-of-package R-value of about 5.1, and an installed R-value (at 25% compression) of about 4.2. In another variation, duct wrap has a nominal thickness of about 2 in, a nominal density of about 0.75 lbs/ft³, an out-of-package R-value of about 6.8, and an installed R-value (at 25% compression) of about 5.6. In another variation, duct wrap has a nominal thickness of about 2.2 in, a nominal density of about 0.75 lbs/ft³, an out-of-package R-value of about 7.4, and an installed R-value (at 25% compression) of about 6. In another variation, duct wrap has a nominal thickness of about 2.5 in, a nominal density of about 0.75 lbs/ft³, an out-of-package R-value of about 8.5, and an installed R-value (at 25% compression) of about 7. In another variation, duct wrap has a nominal thickness of about 3 in, a nominal density of about 0.75 lbs/ft³, an out-of-package R-value of about 10.2, and an installed R-value (at 25% compression) of about 8.4.

In another variation, duct wrap has a nominal thickness of about 1 in, a nominal density of about 1 lbs/ft³, an out-of-package R-value of about 3.7, and an installed R-value (at 25% compression) of about 3. In another variation, duct wrap has a nominal thickness of about 1.5 in, a nominal density of about 1 lbs/ft³, an out-of-package R-value of about 5.6, and an installed R-value (at 25% compression) of about 4.5. In another variation, duct wrap has a nominal thickness of about 2 in, a nominal density of about 1 lbs/ft³, an out-of-package R-value of about 7.4, and an installed R-value (at 25% compression) of about 6.

In another variation, duct wrap has a nominal thickness of about 1 in, a nominal density of about 1.5 lbs/ft³, an out-of-package R-value of about 4.1, and an installed R-value (at 25% compression) of about 3.2. In another variation, duct wrap has a nominal thickness of about 1.5 in, a nominal density of about 1.5 lbs/ft³, an out-of-package R-value of about 6.1, and an installed R-value (at 25% compression) of about 4.8. In another variation, duct wrap has a nominal thickness of about 2 in, a nominal density of about 1.5 lbs/ft³, an out-of-package R-value of about 8.2, and an installed R-value (at 25% compression) of about 6.4.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by elevated temperature board (850° F.) insulation. Elevated temperature board (850° F.) insulation is a uniformly textured, resilient, high temperature thermal insulating and sound absorbing material including glass fibers that are bonded with a high-temperature thermoset binder. The thermoset binder minimizes exothermic temperature rise and protects against punking and fusing of the product when applied at maximum operating temperature. The binder content of this product is related to maintaining the product's rated temperature resistance and reducing the smoke and off-gassing generated during the decomposition of the binder during product heat-up. This product may be used for high temperature applications for hot surface temperatures up to about 850° F. at a maximum of about 6-in thickness with no heat-up cycle required. Thermal properties for elevated temperature board (850° F.) insulation are determined in accordance with ASTM C177. Thickness and/or density are determined in accordance with ASTM C 167. Elevated temperature board (850° F.) insulation typically requires a nominal fiber diameter of about 27±about 3 ht, and a nominal loss on ignition of about 6±about 1%.

Illustratively, elevated temperature board (850° F.) insulation at a nominal density of about 3 lbs/ft³ displays thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 100° F., 0.25; 200° F., 0.33; 300° F., 0.40; 400° F., 0.49; and 500° F., 0.57, e.g., in such embodiments the nominal density can be about 2.8 lbs/ft³.

In one illustrative variation, elevated temperature board (850° F.) insulation has a nominal density of about 2.8 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2333 lbs/ft². In another variation, elevated temperature board (850° F.) insulation has a nominal density of 2.8 lbs/ft³, a nominal thickness of about 1.2 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2917 lbs/ft². In another variation, elevated temperature board (850° F.) insulation has a nominal density of 2.8 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3500 lbs/ft². In another variation, elevated temperature board (850° F.) insulation has a nominal density of 2.8 lbs/ft³, a nominal thickness of about 1.7 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4083 lbs/ft². In another variation, elevated temperature board (850° F.) insulation has a nominal density of 2.8 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.5 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4667 lbs/ft². In another variation, elevated temperature board (850° F.) insulation has a nominal density of 2.8 lbs/ft³, a nominal thickness of about 2.5 in, and a nominal weight of about 0.6 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.5833 lbs/ft². In another variation, elevated temperature board (850° F.) insulation has a nominal density of 2.8 lbs/ft³, a nominal thickness of about 3 in, and a nominal weight of about 0.7 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.7000 lbs/ft². In another variation, elevated temperature board (850° F.) insulation has a nominal density of 2.8 lbs/ft³, a nominal thickness of about 4 in, and a nominal weight of about 0.9 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.9333 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by elevated temperature batt (1000° F.) and blanket (1000° F.) insulation. Elevated temperature batt (1000° F.) and blanket (1000° F.) insulation is a uniformly textured, resilient, high temperature thermal insulating and sound absorbing material including glass fibers that are bonded with a high-temperature thermoset binder. The thermoset binder minimizes exothermic temperature rise and protects against punking and fusing of the product when applied at maximum operating temperature. The binder content of this product is related to maintaining the product's rated temperature resistance and reducing the smoke and off-gassing generated during the decomposition of the binder during product heat-up. This product may be used for high temperature applications for hot surface temperatures up to about 1000° F. at a maximum of about 6-in thickness with no heat-up cycle required. Thermal properties for elevated temperature batt (1000° F.) and blanket (1000° F.) insulation are determined in accordance with ASTM C177. Thickness and/or density are determined in accordance with ASTM C 167. Elevated temperature batt (1000° F.) and blanket (1000° F.) insulation typically requires a nominal fiber diameter of about 22±about 2 ht, and a nominal loss on ignition of about 3−about 0.5%/+about 2%.

Illustratively, elevated temperature batt (1000° F.) and blanket (1000° F.) insulation at a nominal density of about 2 lbs/ft³ displays thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 100° F., 0.24; 200° F., 0.33; 300° F., 0.44; 400° F., 0.57; and 500° F., 0.72, e.g., in such embodiments the nominal density can be about 1.6 lbs/ft³.

In one illustrative variation, elevated temperature batt (1000° F.) and blanket (1000° F.) insulation has a nominal density of 1.6 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2000 lbs/ft². In another variation, elevated temperature batt (1000° F.) and blanket (1000° F.) insulation has a nominal density of 1.6 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2667 lbs/ft². In another variation, elevated temperature batt (1000° F.) and blanket (1000° F.) insulation has a nominal density of 1.6 lbs/ft³, a nominal thickness of about 2.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3333 lbs/ft². In another variation, elevated temperature batt (1000° F.) and blanket (1000° F.) insulation has a nominal density of 1.6 lbs/ft³, a nominal thickness of about 3 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4000 lbs/ft². In another variation, elevated temperature batt (1000° F.) and blanket (1000° F.) insulation has a nominal density of 1.6 lbs/ft³, a nominal thickness of about 3.5 in, and a nominal weight of about 0.5 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4667 lbs/ft². In another variation, elevated temperature batt (1000° F.) and blanket (1000° F.) insulation has a nominal density of 1.6 lbs/ft³, a nominal thickness of about 4 in, and a nominal weight of about 0.5 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.5333 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by elevated temperature panel (1000° F.) insulation. Elevated temperature panel (1000° F.) insulation is a uniformly textured, resilient, high temperature thermal insulating and sound absorbing material including glass fibers that are bonded with a high-temperature thermoset binder. The thermoset binder minimizes exothermic temperature rise and protects against punking and fusing of the product when applied at maximum operating temperature. The binder content of this product is related to maintaining the product's rated temperature resistance and reducing the smoke and off-gassing generated during the decomposition of the binder during product heat-up. This product may be used for high temperature applications for hot surface temperatures up to about 1000° F. at a maximum of about 6-in thickness with no heat-up cycle required. Thermal properties for elevated temperature panel (1000° F.) insulation are determined in accordance with ASTM C177. Thickness and/or density are determined in accordance with ASTM C 167. Elevated temperature panel (1000° F.) insulation typically requires a nominal fiber diameter of about 22±about 2 ht, and a nominal loss on ignition of about 3−about 0.5/+about 2%.

Illustratively, elevated temperature panel (1000° F.) insulation at a nominal density of about 2 lbs/ft³ displays thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 100° F., 0.25; 200° F., 0.32; 300° F., 0.40; 400° F., 0.52; and 500° F., 0.68, e.g., in such embodiments the nominal density can be about 2.4 lbs/ft³.

In one illustrative variation, elevated temperature panel (1000° F.) insulation has a nominal density of 2.4 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2000 lbs/ft². In another variation, elevated temperature panel (1000° F.) insulation has a nominal density of 2.4 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3000 lbs/ft². In another variation, elevated temperature panel (1000° F.) insulation has a nominal density of 2.4 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4000 lbs/ft². In another variation, elevated temperature panel (1000° F.) insulation has a nominal density of 2.4 lbs/ft³, a nominal thickness of about 2.25 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4500 lbs/ft². In another variation, elevated temperature panel (1000° F.) insulation has a nominal density of 2.4 lbs/ft³, a nominal thickness of about 2.5 in, and a nominal weight of about 0.5 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.5000 lbs/ft². In another variation, elevated temperature panel (1000° F.) insulation has a nominal density of 2.4 lbs/ft³, a nominal thickness of about 3 in, and a nominal weight of about 0.6 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.6000 lbs/ft². In another variation, elevated temperature panel (1000° F.) insulation has a nominal density of 2.4 lbs/ft³, a nominal thickness of about 3.5 in, and a nominal weight of about 0.7 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.7000 lbs/ft². In another variation, elevated temperature panel (1000° F.) insulation has a nominal density of 2.4 lbs/ft³, a nominal thickness of about 4 in, and a nominal weight of about 0.8 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.8000 lbs/ft². In another variation, elevated temperature panel (1000° F.) insulation has a nominal density of 2.4 lbs/ft³, a nominal thickness of about 4.5 in, and a nominal weight of about 0.9 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.9000 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by elevated temperature fabrication board (850° F.) insulation. Elevated temperature fabrication board (850° F.) insulation is a uniformly textured, resilient, high temperature thermal insulating and sound absorbing material including glass fibers that are bonded with a high-temperature thermoset binder. The thermoset binder minimizes exothermic temperature rise and protects against punking and fusing of the product when applied at maximum operating temperature. The binder content of this product is related to maintaining the product's rated temperature resistance and reducing the smoke and off-gassing generated during the decomposition of the binder during product heat-up. This product may be used for high temperature applications (e.g., use by fabricators for the manufacture of pipe and tank insulation) for hot surface temperatures up to about 850° F. at a maximum of about 6-in thickness with no heat-up cycle required. Thermal properties for elevated temperature fabrication board (850° F.) insulation are determined in accordance with ASTM C177. Thickness and/or density are determined in accordance with ASTM C 167. Elevated temperature board (850° F.) insulation typically requires a nominal fiber diameter of about 27±about 3 ht, and a nominal loss on ignition of about 6±about 1%.

Illustratively, elevated temperature fabrication board (850° F.) insulation at a nominal density of about 3 lbs/ft³ displays thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 100° F., 0.25; 200° F., 0.33; 300° F., 0.40; 400° F., 0.49; and 500° F., 0.57, e.g., in such embodiments the nominal density can be about 2.8 lbs/ft³.

In one illustrative variation, elevated temperature fabrication board (850° F.) insulation has a nominal density of about 2.8 lbs/ft³, a nominal thickness of about 4 in, and a nominal weight of about 0.9 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.9333 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by elevated temperature blanket (1000° F.) insulation. Elevated temperature blanket (1000° F.) insulation is a uniformly textured, resilient, high temperature thermal insulating and sound absorbing material including glass fibers that are bonded with a high-temperature thermoset binder. The thermoset binder minimizes exothermic temperature rise and protects against punking and fusing of the product when applied at maximum operating temperature. The binder content of this product is related to maintaining the product's rated temperature resistance and reducing the smoke and off-gassing generated during the decomposition of the binder during product heat-up. This product may be used for high temperature applications for operating temperatures up to about 1000° F. with no heat-up cycle required (e.g., for industrial furnaces, panel systems, marine applications, and irregular surfaces). Thermal properties for elevated temperature blanket (1000° F.) insulation are determined in accordance with ASTM C177. Thickness and/or density are determined in accordance with ASTM C 167. Elevated temperature blanket (1000° F.) insulation typically requires a nominal fiber diameter of about 22±about 2 ht, and a nominal loss on ignition of about 3−about 0.5/+about 2%.

Illustratively, elevated temperature blanket (1000° F.) insulation at a nominal density of about 1 lbs/ft³ displays thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 100° F., 0.28; 200° F., 0.38; 300° F., 0.52; 400° F., 0.70; and 500° F., 0.90, e.g., in such embodiments the nominal density can be about 1.1 lbs/ft³.

In one illustrative variation, elevated temperature blanket (1000° F.) insulation has a nominal density of 1.1 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.09 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.0917 lbs/ft². In another variation, elevated temperature blanket (1000° F.) insulation has a nominal density of 1.1 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.1 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1375 lbs/ft². In another variation, elevated temperature blanket (1000° F.) insulation has a nominal density of 1.1 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1833 lbs/ft². In another variation, elevated temperature blanket (1000° F.) insulation has a nominal density of 1.1 lbs/ft³, a nominal thickness of about 2.5 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2292 lbs/ft². In another variation, elevated temperature blanket (1000° F.) insulation has a nominal density of 1.1 lbs/ft³, a nominal thickness of about 3 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2750 lbs/ft². In another variation, elevated temperature blanket (1000° F.) insulation has a nominal density of 1.1 lbs/ft³, a nominal thickness of about 3.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3208 lbs/ft². In another variation, elevated temperature blanket (1000° F.) insulation has a nominal density of 1.1 lbs/ft³, a nominal thickness of about 4 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3667 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by flexible duct media. Flexible duct media is a uniformly textured, resilient, thermal insulating and sound absorbing material including glass fibers that are bonded with a thermoset binder. This product may be used in the manufacture of flexible duct insulation for air handling systems. Thermal properties for flexible duct media are determined in accordance with ASTM C177 and ASTM C653. Thickness and/or density are determined in accordance with ASTM C 167. Flexible duct media typically requires a nominal fiber diameter of about 20±about 2 ht, and a nominal loss on ignition of about 6±about 1%.

Illustratively, flexible duct media displays Type I thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 75° F., 0.36; 100° F., 0.39; 200° F., 0.55; and 300° F., 0.76. Further, flexible duct media displays Type II thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 75° F., 0.31; 100° F., 0.33; 200° F., 0.44; and 300° F., 0.60.

In one illustrative variation, flexible duct media has a nominal thickness of about 1.2 in, an R-value of about 4.2, and a nominal weight of about 0.08 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.0825 lbs/ft². In another variation, flexible duct media has a nominal thickness of about 2 in, an R-value of about 6, and a nominal weight of about 0.1 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1150 lbs/ft². In another variation, flexible duct media has a nominal thickness of about 2.6 in, an R-value of about 8, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1500 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by insulation board. Insulation board is a thermal and acoustical insulation product including glass fibers that are preformed into boards and bonded with a thermoset binder. This product may be manufactured plain, or faced with factory-applied foil-scrim-kraft (FSK), white poly-scim-kraft (PSK), or all-service-jacket (ASJ) facings. Insulation board may be used in heating and air conditioning ducts, power and process equipment, boiler and stack installations, metal and masonry walls, wall and roof panel systems, curtain wall assemblies and cavity walls. Thermal conductivity and acoustical properties for insulation board are determined in accordance with ASTM C177 and ASTM C423 (Type A Mounting), respectively. Thickness and/or density are determined in accordance with ASTM C 167. Insulation board insulation typically requires a nominal fiber diameter of about 20±about 3 ht for less than about 3 lb/ft³ board density, and about 27±about 3 ht for greater than or equal to 3 lbs/ft³ board density, and nominal loss on ignition of about 11±about 2%.

Illustratively, insulation board at a nominal density of about 2 lbs/ft³ displays noise reduction coefficients in the range from about 0.80 to about 1.05, and thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 75° F., 0.24; 100° F., 0.25; 200° F., 0.33; and 300° F., 0.42, e.g., in such embodiments the nominal density can be about 1.6 lbs/ft³. Further, insulation board at a nominal density of about 3 lbs/ft³ displays noise reduction coefficients in the range from about 0.65 to about 1.10, and thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 75° F., 0.23; 100° F., 0.24; 200° F., 0.29; and 300° F., 0.37. Further, insulation board at a nominal density of about 6 lbs/ft³ displays noise reduction coefficients in the range from about 0.5 to about 1.00, and thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 75° F., 0.22; 100° F., 0.23; 200° F., 0.27; and 300° F., 0.34.

In one illustrative variation, insulation board has a nominal density of about 1.6 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.1 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1375 lbs/ft². In another variation, insulation board has a nominal density of about 1.6 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2063 lbs/ft². In another variation, insulation board has a nominal density of about 1.6 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2750 lbs/ft². In another variation, insulation board has a nominal density of about 1.6 lbs/ft³, a nominal thickness of about 2.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3438 lbs/ft². In another variation, insulation board has a nominal density of about 1.6 lbs/ft³, a nominal thickness of about 3 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4125 lbs/ft². In another variation, insulation board has a nominal density of about 1.6 lbs/ft³, a nominal thickness of about 3.5 in, and a nominal weight of about 0.5 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4813 lbs/ft². In another variation, insulation board has a nominal density of about 1.6 lbs/ft³, a nominal thickness of about 4 in, and a nominal weight of about 0.6 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.5500 lbs/ft².

In another variation, insulation board has a nominal density of about 2.2 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1875 lbs/ft². In another variation, insulation board has a nominal density of about 2.2 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2813 lbs/ft². In another variation, insulation board has a nominal density of about 2.2 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3750 lbs/ft². In another variation, insulation board has a nominal density of about 2.2 lbs/ft³, a nominal thickness of about 2.5 in, and a nominal weight of about 0.5 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4688 lbs/ft². In another variation, insulation board has a nominal density of about 2.2 lbs/ft³, a nominal thickness of about 3 in, and a nominal weight of about 0.6 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.5625 lbs/ft². In another variation, insulation board has a nominal density of about 2.2 lbs/ft³, a nominal thickness of about 3.5 in, and a nominal weight of about 0.7 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.6563 lbs/ft². In another variation, insulation board has a nominal density of about 2.2 lbs/ft³, a nominal thickness of about 4 in, and a nominal weight of about 0.8 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.7500 lbs/ft².

In another variation, insulation board has a nominal density of about 3 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2500 lbs/ft². In another variation, insulation board has a nominal density of about 3 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3750 lbs/ft². In another variation, insulation board has a nominal density of about 3 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.5 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.5000 lbs/ft². In another variation, insulation board has a nominal density of about 3 lbs/ft³, a nominal thickness of about 2.5 in, and a nominal weight of about 0.6 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.6250 lbs/ft². In another variation, insulation board has a nominal density of about 3 lbs/ft³, a nominal thickness of about 3 in, and a nominal weight of about 0.8 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.7500 lbs/ft². In another variation, insulation board has a nominal density of about 3 lbs/ft³, a nominal thickness of about 3.5 in, and a nominal weight of about 0.9 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.8750 lbs/ft². In another variation, insulation board has a nominal density of about 3 lbs/ft³, a nominal thickness of about 4 in, and a nominal weight of about 1.0 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1.0000 lbs/ft².

In another variation, insulation board has a nominal density of about 4.25 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3542 lbs/ft². In another variation, insulation board has a nominal density of about 4.25 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.5 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.5313 lbs/ft². In another variation, insulation board has a nominal density of about 4.25 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.7 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.7083 lbs/ft². In another variation, insulation board has a nominal density of about 4.25 lbs/ft³, a nominal thickness of about 2.5 in, and a nominal weight of about 0.9 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.8854 lbs/ft².

In another variation, insulation board has a nominal density of about 6 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.5 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.5000 lbs/ft². In another variation, insulation board has a nominal density of about 6 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.7 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.7500 lbs/ft². In another variation, insulation board has a nominal density of about 6 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 1.0 lbs/ft², e.g., in such embodiments the nominal weight can be about 1.0000 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by self-cleaning range insulation. Self-cleaning range insulation is a uniformly textured, resilient, high temperature thermal and acoustical insulation material including glass fibers that are bonded with a high temperature thermoset binder. The thermoset binder minimizes exothermic temperature rise and protects against punking and fusing of the product when applied at maximum operating temperature. The binder content of this product is related to maintaining the product's rated temperature resistance and reducing the smoke and off-gassing generated during the decomposition of the binder during product heat-up. This product may be used for high temperature range applications for self-cleaning ovens and is suitable for operating temperatures up to about 1000° F. with no heat-up cycle required. Self-cleaning range insulation may be used by OEM range manufacturers as thermal insulation for energy conservation and reduced surface temperatures of self-cleaning ranges. This product is associated with minimal smoke and odor on the initial start-up of the range. Thermal conductivity properties for self-cleaning range insulation are determined in accordance with ASTM C177 and ASTM C518. Thickness and/or density are determined in accordance with ASTM C 167. Self-cleaning range insulation typically requires a nominal fiber diameter of about 22±about 2 ht, and a nominal loss on ignition of about 2.0+about 2.0/−about 0.5%.

Illustratively, self-cleaning range insulation at a nominal density of about 1 lbs/ft³ displays a thermal conductivity of 0.26 BTU in/hr ft²° F. at 75° F., e.g., in such embodiments the nominal density can be about 1.1 lbs/ft³. Illustratively, self-cleaning range insulation at a nominal density of about 1.5 lbs/ft³ displays a thermal conductivity of 0.24 BTU in/hr ft²° F. at 75° F. Illustratively, self-cleaning range insulation at a nominal density of about 2 lbs/ft³ displays a thermal conductivity of 0.23 BTU in/hr ft²° F. at 75° F.

In one illustrative variation, self-cleaning range insulation has a nominal density of about 1.1 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.09 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.0917 lbs/ft². In another variation, self-cleaning range insulation has a nominal density of about 1.1 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.1 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1375 lbs/ft². In another variation, self-cleaning range insulation has a nominal density of about 1.1 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1833 lbs/ft². In another variation, self-cleaning range insulation has a nominal density of about 1.1 lbs/ft³, a nominal thickness of about 3 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2750 lbs/ft². In another variation, self-cleaning range insulation has a nominal density of about 1.1 lbs/ft³, a nominal thickness of about 4 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3667 lbs/ft².

In another variation, self-cleaning range insulation has a nominal density of about 1.5 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.1 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1250 lbs/ft². In another variation, self-cleaning range insulation has a nominal density of about 1.5 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1875 lbs/ft². In another variation, self-cleaning range insulation has a nominal density of about 1.5 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2500 lbs/ft². In another variation, self-cleaning range insulation has a nominal density of about 1.5 lbs/ft³, a nominal thickness of about 3 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3750 lbs/ft².

In another variation, self-cleaning range insulation has a nominal density of about 2 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1667 lbs/ft². In another variation, self-cleaning range insulation has a nominal density of about 2 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2500 lbs/ft². In another variation, self-cleaning range insulation has a nominal density of about 2 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3333 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by standard range insulation. Standard range insulation is a uniformly textured, resilient, high temperature thermal and acoustical insulation material including glass fibers that are bonded with a high temperature thermoset binder. The thermoset binder minimizes exothermic temperature rise and protects against punking and fusing of the product when applied at maximum operating temperature. The binder content of this product is related to maintaining the product's rated temperature resistance and reducing the smoke and off-gassing generated during the decomposition of the binder during product heat-up. This product may be used for high temperature range applications for non-self-cleaning ovens and is suitable for operating temperatures up to about 1000° F. with no heat-up cycle required. Standard range insulation is used by OEM range manufacturers as thermal insulation for energy conservation and reduced surface temperatures of standard ranges. This product is associated with minimal smoke and odor on the initial start-up of the range. Thermal conductivity properties for standard range insulation are determined in accordance with ASTM C177 and ASTM C518. Thickness and/or density are determined in accordance with ASTM C 167. Standard range insulation typically requires a nominal fiber diameter of about 22+about 2 ht, and a nominal loss on ignition of about 3.0+about 2.0/−about 0.5%.

Illustratively, standard insulation at a nominal density of about 1 lbs/ft³ displays a thermal conductivity of 0.26 BTU in/hr ft²° F. at 75° F., e.g., in such embodiments the nominal density can be about 1.1 lbs/ft³. Illustratively, standard range insulation at a nominal density of about 1.5 lbs/ft³ displays a thermal conductivity of 0.24 BTU in/hr ft²° F. at 75° F. Illustratively, standard range insulation at a nominal density of about 2 lbs/ft³ displays a thermal conductivity of 0.23 BTU in/hr ft²° F. at 75° F.

In one illustrative variation, standard range insulation has a nominal density of about 1.1 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.09 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.0917 lbs/ft². In another variation, standard range insulation has a nominal density of about 1.1 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.1 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1375 lbs/ft². In another variation, standard range insulation has a nominal density of about 1.1 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1833 lbs/ft². In another variation, standard range insulation has a nominal density of about 1.1 lbs/ft³, a nominal thickness of about 3 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2750 lbs/ft². In another variation, standard range insulation has a nominal density of about 1.1 lbs/ft³, a nominal thickness of about 4 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3667 lbs/ft².

In another variation, standard range insulation has a nominal density of about 1.5 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.1 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1250 lbs/ft². In another variation, standard range insulation has a nominal density of about 1.5 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1875 lbs/ft². In another variation, standard range insulation has a nominal density of about 1.5 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2500 lbs/ft². In another variation, standard range insulation has a nominal density of about 1.5 lbs/ft³, a nominal thickness of about 3 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3750 lbs/ft².

In another variation, standard range insulation has a nominal density of about 2 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1667 lbs/ft². In another variation, standard range insulation has a nominal density of about 2 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2500 lbs/ft². In another variation, standard range insulation has a nominal density of about 2 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3333 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by KN series insulation. KN series insulation is a uniformly textured, resilient, thermal insulating and sound absorbing material including glass fibers bonded with a thermoset binder. This product has sufficient tensile strength to allow for die-cutting, fabrication, lamination, and installation in OEM applications. KN series insulation may be used as thermal and/or acoustical insulation for appliance, equipment, industrial, commercial, and marine applications. Thermal conductivity and acoustical properties for KN series insulation are determined in accordance with ASTM C177 and ASTM C423 (Type A Mounting), respectively. Thickness and/or density are determined in accordance with ASTM C 167. KN series insulation typically requires a nominal fiber diameter of about 18±about 2 ht, and nominal loss on ignition of about 5% or about 8%±about 1%.

Illustratively, KN series insulation at a nominal density of about 0.75 lbs/ft³ displays thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 50° F., 0.28; 75° F., 0.29; 100° F., 0.31; 125° F., 0.33; 150° F., 0.36; 175° F., 0.39; and 200° F., 0.43. Illustratively, KN series insulation at a nominal density of about 1.0 lbs/ft³ displays thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 50° F., 0.26; 75° F., 0.27; 100° F., 0.29; 125° F., 0.31; 150° F., 0.34; 175° F., 0.37; and 200° F., 0.40. Illustratively, KN series insulation at a nominal density of about 1.5 lbs/ft³ displays thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 50° F., 0.23; 75° F., 0.24; 100° F., 0.26; 125° F., 0.28; 150° F., 0.31; 175° F., 0.33; and 200° F., 0.36.

In one illustrative variation, KN series insulation has a nominal density of about 0.75 lbs/ft³, a nominal thickness of about 1 in, 1.5 in, 2 in, 2.5 in, and 3 in, and a noise reduction coefficient of about 0.75 at 1.5-in thickness. In another variation, KN series insulation has a nominal density of about 1 lbs/ft³, a nominal thickness of about 0.75 in, 1 in, 1.5 in, 2 in, 2.5 in, and 3 in, and a noise reduction coefficient of about 0.65 at 1-in thickness, and about 0.85 at 1.5-in thickness. In another variation, KN series insulation has a nominal density of about 1.5 lbs/ft³, a nominal thickness of about 0.75 in, 1 in, 1.5 in, and 2 in, and a noise reduction coefficient of about 0.65 at 1-in thickness, about 0.90 at 1.5-in thickness, and about 1.05 at 2-in thickness. In another variation, KN series insulation has a nominal density of about 2 lbs/ft³, a nominal thickness of about 0.75 in, 1 in, 1.5 in, and 2 in, and a noise reduction coefficient of about 0.70 at 1-in thickness, about 0.90 at 1.5-in thickness, and about 1.05 at 2-in thickness. In another variation, KN series insulation has a nominal density of about 2.5 lbs/ft³, and a nominal thickness of about 0.75 in, 1 in, and 1.5 in.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by metal building insulation. Metal building insulation is a uniformly textured, resilient, thermal insulating and sound absorbing material including glass fibers bonded with a thermoset binder. This product has a facing (bottom) surface suitable for facing adherence and sufficient tensile strength to allow for fabrication, lamination, and installation. Metal building insulation may be used for thermal and acoustical insulation in the walls and ceilings of pre-engineered metal buildings for energy conservation and condensation control. Thermal conductivity and acoustical properties for metal building insulation are determined in accordance with ASTM C 518/C 653 and ASTM C423 (Type A Mounting), respectively. Thickness and/or density are determined in accordance with ASTM C 167. Metal building insulation typically requires a nominal fiber diameter of about 18±about 2 ht, and nominal loss on ignition of about 8±about 1%.

In one illustrative variation, metal building insulation has a nominal thickness of about 3.25 in, and an R-value of about 10. In another variation, metal building insulation has a nominal thickness of about 3.5 in, an R-value of about 11, and a noise reduction coefficient of about 0.95. In another variation, metal building insulation has a nominal thickness of about 4.25 in, an R-value of about 13, and a noise reduction coefficient of about 1.00. In another variation, metal building insulation has a nominal thickness of about 5 in, and an R-value of about 16. In another variation, metal building insulation has a nominal thickness of about 6 in, an R-value of about 19, and a noise reduction coefficient of about 1.15. In another variation, metal building insulation has a nominal thickness of about 8 in, and an R-value of about 25. In another variation, metal building insulation has a nominal thickness of about 9.5 in, and an R-value of about 30.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by manufactured housing insulation rolls. Manufactured housing insulation rolls are a uniformly textured, resilient, thermal insulating and sound absorbing material including glass fibers that are bonded with a thermoset binder. This product may be manufactured either with or without a vapor retarding facing on one face of the product. Manufactured housing insulation rolls may be used in manufactured houses as a thermal insulation and sound absorbing material in the walls, floors, and ceilings. Thermal properties for manufactured housing insulation rolls are determined in accordance with ASTM C 653 as per ASTM C665. Thickness and/or density are determined in accordance with ASTM C167. Manufactured housing insulation rolls typically require a nominal fiber index of about 19±about 2 units or a nominal fiber diameter of about 18±about 2 ht, and nominal loss on ignition of about 4.5±about 0.5%.

In one illustrative variation, a manufactured housing insulation roll has an R-value of about 5, a nominal thickness of about 1.5 in, and a nominal weight of about 0.09 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.0894 lbs/ft². In another variation, a manufactured housing insulation roll has an R-value of about 7, a nominal thickness of about 2.25 in, and a nominal weight of about 0.1 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1200 lbs/ft². In another variation, a manufactured housing insulation roll has an R-value of about 11, a nominal thickness of about 3.5 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1580 lbs/ft². In another variation, a manufactured housing insulation roll has an R-value of about 13, a nominal thickness of about 3.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2600 lbs/ft². In another variation, a manufactured housing insulation roll has an R-value of about 14, a nominal thickness of about 3.5 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3600 lbs/ft². In another variation, a manufactured housing insulation roll has an R-value of about 19, a nominal thickness of about 6.25 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2600 lbs/ft². In another variation, a manufactured housing insulation roll has an R-value of about 25, a nominal thickness of about 8.25 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3285 lbs/ft². In another variation, a manufactured housing insulation roll has an R-value of about 30, a nominal thickness of about 9.5 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3762 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by pipe insulation-1000° F. Pipe insulation-1000° F. is a slit, one-piece, hollow cylindrical-molded, heavy-density insulation including glass fibers that are bonded with a thermoset binder typically produced in about 3-in lengths with or without a factory-applied jacket. The jacket is a white-kraft paper bonded to aluminum foil and reinforced with glass fibers, and the longitudinal flap of the jacket is available with or without a self-sealing adhesive. Pipe insulation-1000° F. may be used in power, process, and industrial applications and commercial and institutional buildings where fire safety, resistance to physical abuse, and a finished building appearance is desired. This product is intended for use on systems with operating temperatures from about 0° F. to about 1000° F. Thermal conductivity for pipe insulation-1000° F. is determined in accordance with ASTM C 335.

Illustratively, pipe insulation-1000° F. displays thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 75° F., 0.23; 100° F., 0.24; 200° F., 0.28; 300° F., 0.34; 400° F., 0.42; 500° F., 0.51; and 600° F., 0.62.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by KWIK FLEX pipe and tank insulation. KWIK FLEX pipe and tank insulation is a thermal insulation product including glass fibers preformed into a semi-rigid blanket bonded by a thermoset resin and packaged in a roll form. It is available faced with a factory-applied all-service jacket (ASJ), foil-scrim-kraft (FSK), or white poly-scrim (PSK) vapor retarder jacket. This product is typically used on tanks, vessels, and large-diameter (greater than about 10-in) pipes. It can also be used for curved or irregular surfaces that require finished characteristics of rigid fiber glass insulation. Thermal conductivity for KWIK FLEX pipe and tank insulation is determined in accordance with ASTM C 177. Thickness and/or density are determined in accordance with ASTM C 167. KWIK FLEX pipe and tank insulation typically requires a nominal fiber diameter of about 22±about 2 ht, and a nominal loss on ignition of about 6±about 2%.

Illustratively, KWIK FLEX pipe and tank insulation displays thermal conductivity (in BTU in/hr ft²° F.) as a function of mean temperature as follows: 75° F., 0.24; 100° F., 0.25; 200° F., 0.32; 300° F., 0.39; 400° F., 0.49; and 500° F., 0.61.

In one illustrative variation, KWIK FLEX pipe and tank insulation has a nominal density of about 2.5 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2344 lbs/ft². In another variation, KWIK FLEX pipe and tank insulation has a nominal density of about 2.5 lbs/ft³, a nominal thickness of about 1.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3215 lbs/ft². In another variation, KWIK FLEX pipe and tank insulation has a nominal density of about 2.5 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4167 lbs/ft². In another variation, KWIK FLEX pipe and tank insulation has a nominal density of about 2.5 lbs/ft³, a nominal thickness of about 3 in, and a nominal weight of about 0.6 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.6250 lbs/ft². In another variation, KWIK FLEX pipe and tank insulation has a nominal density of about 2.5 lbs/ft³, a nominal thickness of about 3.5 in, and a nominal weight of about 0.7 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.7290 lbs/ft². In another variation, KWIK FLEX pipe and tank insulation has a nominal density of about 2.5 lbs/ft³, a nominal thickness of about 4 in, and a nominal weight of about 0.9 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.9380 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by residential building insulation in the form of batts. Residential building insulation is a uniformly textured, resilient, thermal insulating and sound absorbing material including glass fibers that are bonded with a thermoset binder. This product may be manufactured either with or without a vapor retarding facing on one principle face of the product. Unfaced residential building insulation may be friction fit between framing members of walls, ceilings, and floor of buildings. Batts of residential building insulation are precision-cut pieces, ready to install in framing cavities, packaged in preformed bags and unitized to a particular number of bags per unit depending on R-value, i.e., thermal resistance (determined in accordance with ASTM C 653 as per ASTM C665), and product width. Thickness and/or density are determined in accordance with ASTM C 167. Such batts typically require a nominal fiber index of about 16.5±about 2 units or a nominal fiber diameter of about 18±about 2 ht, and nominal loss on ignition of about 4.5±about 0.5%.

In one illustrative variation, a batt of residential building insulation has an R-value of about 3, a nominal thickness of about 0.75 in, and a nominal weight of about 0.09 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.0938 lbs/ft². In another variation, a batt of residential building insulation has an R-value of about 5, a nominal thickness of about 1.5 in, and a nominal weight of about 0.09 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.0894 lbs/ft². In another variation, a batt of residential building insulation has an R-value of about 11, a nominal thickness of about 3.5 in, and a nominal weight of about 0.1 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1420 lbs/ft². In another variation, a batt of residential building insulation has an R-value of about 13, a nominal thickness of about 3.5 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2316 lbs/ft². In another variation, a batt of residential building insulation has an R-value of about 19, a nominal thickness of about 6.25 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2340 lbs/ft². In another variation, a batt of residential building insulation has an R-value of about 22, a nominal thickness of about 6.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3202 lbs/ft². In another variation, a batt of residential building insulation has an R-value of about 26, a nominal thickness of about 9 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3004 lbs/ft². In another variation, a batt of residential building insulation has an R-value of about 30, a nominal thickness of about 9.5 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3897 lbs/ft². In another variation, a batt of residential building insulation has an R-value of about 30, a nominal thickness of about 10 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3631 lbs/ft². In another variation, a batt of residential building insulation has an R-value of about 38, a nominal thickness of about 12 in, and a nominal weight of about 0.5 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4957 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by residential building insulation (as described above) in the form of rolls. Rolls of residential building insulation are precision-cut pieces ready to be cut-to-length to fit in variously sized stud cavities. This insulation product is initially compressed in roll-up equipment and then further compressed using secondary compression by means of vacuum packaging or a roll-in-bag unit. The resulting roll in then placed in a protective sleeve of a preformed bag. Such rolls typically require a nominal fiber index of about 16.5±about 2 units or a nominal fiber diameter of about 18±about 2 ht, and nominal loss on ignition of about 4.5±about 0.5%; alternatively, when a larger fiber diameter is required for increased mechanical strength, such rolls may require a nominal fiber index of about 19±about 2 units or a nominal fiber diameter of about 20±about 2 ht, and nominal loss on ignition of about 4.5±about 0.5%.

In one illustrative variation, a roll of residential building insulation has an R-value of about 11, a nominal thickness of about 3.5 in, and a nominal weight of about 0.1 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1420 lbs/ft². In another variation, a roll of residential building insulation has an R-value of about 19, a nominal thickness of about 6.25 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2340 lbs/ft². In another variation, a roll of residential building insulation has an R-value of about 26, a nominal thickness of about 8.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3004 lbs/ft². In another variation, a roll of residential building insulation with a nominal fiber diameter of 20±2 ht has an R-value of about 11, a nominal thickness of about 3.5 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1580 lbs/ft². In another variation, a roll of residential building insulation with a nominal fiber diameter of 20±2 ht has an R-value of about 13, a nominal thickness of about 3.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2600 lbs/ft². In another variation, a roll of residential building insulation with a nominal fiber diameter of 20±2 ht has an R-value of about 19, a nominal thickness of about 6.25 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2600 lbs/ft². In another variation, a roll of residential building insulation with a nominal fiber diameter of 20±2 ht has an R-value of about 26, a nominal thickness of about 8.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3285 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by residential building insulation (as described above) in the form of retail rolls. Retail rolls of residential building insulation achieve their finished roll diameter in roll-up equipment. Secondary packaging involves form-fill-seal equipment to allow product identification and protection. Such rolls typically require a nominal fiber index of about 19±about 2 units or a nominal fiber diameter of about 20±about 2 ht, and nominal loss on ignition of about 4.5±about 0.5%.

In one illustrative variation, a retail roll of residential building insulation has an R-value of about 11, a nominal thickness of about 3.5 in, and a nominal weight of about 0.1 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1580 lbs/ft². In another variation, a retail roll of residential building insulation has an R-value of about 13, a nominal thickness of about 3.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2600 lbs/ft². In another variation, a retail roll of residential building insulation has an R-value of about 19, a nominal thickness of about 6.25 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2600 lbs/ft². In another variation, a retail roll of residential building insulation has an R-value of about 25, a nominal thickness of about 8.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3285 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by residential building insulation (as described above) in the form of heavy density batts, including cathedral ceiling heavy density batts. Heavy density batts of residential building insulation are precision-cut pieces, ready to install in framing cavities, packaged in preformed bags and unitized to a particular number of bags per unit. This insulation product includes high-resistivity blankets with a thermal conductivity lower than about 0.275 BTU in/hr ft²° F. Cathedral ceiling heavy density batts may be used to maximize thermal performance of cathedral ceilings while still allowing an unrestricted airspace under the roof deck for proper ventilation and natural convection. Heavy density batts typically require a nominal fiber index of about 16.5±about 2 units or a nominal fiber diameter of about 18±about 2 ht, and nominal loss on ignition of about 4.5±about 0.5%.

In one illustrative variation, a heavy density batt of residential building insulation has an R-value of about 15, a nominal thickness of about 3.5 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3985 lbs/ft². In another variation, a heavy density batt of residential building insulation has an R-value of about 21, a nominal thickness of about 5.5 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4043 lbs/ft². In another variation, a heavy density batt of residential building insulation has an R-value of about 30, a nominal thickness of about 8.25 in, and a nominal weight of about 0.5 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.5069 lbs/ft². In another variation, a heavy density batt of residential building insulation has an R-value of about 38, a nominal thickness of about 10.25 in, and a nominal weight of about 0.7 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.6738 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by residential building insulation (as described above) in the form of staple-free batts. Staple-free batts of residential building insulation are precision-cut pieces, faced to provide a vapor retarder, to be friction fit into framing cavities without stapling in order to reduce labor and time required for installation. Such batts typically require a nominal fiber index of about 16.5±about 2 units or a nominal fiber diameter of about 18±about 2 ht, and nominal loss on ignition of about 4.5±about 0.5%.

In one illustrative variation, a staple-free batt of residential building insulation has an R-value of about 13, a nominal thickness of about 3.5 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2316 lbs/ft². In another variation, a staple-free batt of residential building insulation has an R-value of about 15, a nominal thickness of about 3.5 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3938 lbs/ft². In another variation, a staple-free batt of residential building insulation has an R-value of about 21, a nominal thickness of about 5.5 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4043 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by residential building insulation (as described above) in the form of zip-strip batts. Zip-strip batts of residential building insulation are precision-cut pieces, which are perforated to allow for non-standard frame sizes by tearing (instead of cutting with a knife) length-wise down the product. Zip-strip batts are manufactured with three slits lengthwise in, but not cut completely through, the batt. Such batts typically require a nominal fiber index of about 16.5±about 2 units or a nominal fiber diameter of about 18±about 2 ht, a nominal loss on ignition of about 4.5±about 0.5%, a nominal un-slit depth of about 0.375+about 0.125/−about 0.25 in, and a nominal slit distance of about 2.50±about 0.25 in.

In one illustrative variation, a zip-strip batt of residential building insulation has an R-value of about 13, a nominal thickness of about 3.5 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2316 lbs/ft². In another variation, a zip-strip batt of residential building insulation has an R-value of about 15, a nominal thickness of about 3.5 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3938 lbs/ft². In another variation, a zip-strip batt of residential building insulation has an R-value of about 21, a nominal thickness of about 5.5 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4043 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by commercial building insulation in the form of faced and unfaced batts. Commercial building insulation is a uniformly textured, resilient, thermal insulating and sound absorbing material including glass fibers bonded with a thermoset binder. This product may be manufactured either with or without a vapor retarding facing on one principle face of the product. Unfaced commercial building insulation may be friction fit between framing members of walls, ceilings, and floor of buildings. Batts of commercial building insulation are precision-cut pieces, ready to install in framing cavities, packaged in preformed bags and unitized to a particular number of bags per unit depending on R-value, i.e., thermal resistance (determined in accordance with ASTM C 653 as per ASTM C 665), and product width. Thickness and/or density are determined in accordance with ASTM C 167. Such batts typically require a nominal fiber index of about 16.5±about 2 units or a nominal fiber diameter of about 18±about 2 ht, and nominal loss on ignition of about 4.5±about 0.5%.

In one illustrative variation, a batt of commercial building insulation (faced and unfaced) has an R-value of about 8, a nominal thickness of about 2.5 in, and a nominal weight of about 0.1 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1095 lbs/ft². In another variation, a batt of commercial building insulation (faced and unfaced) has an R-value of about 11, a nominal thickness of about 3.5 in, and a nominal weight of about 0.1 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1420 lbs/ft². In another variation, a batt of commercial building insulation (faced and unfaced) has an R-value of about 13, a nominal thickness of about 3.5 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2316 lbs/ft². In another variation, a batt of commercial building insulation (faced and unfaced) has an R-value of about 19, a nominal thickness of about 6.25 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2340 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by commercial building insulation (as described above) in the form of standard foil-faced batts and fire- and smoke-resistant (FSK) foil-faced batts. Standard foil-faced batts are specified for a low-emittance surface and/or reduced vapor permeance property, and are not rated for fire propagation resistance. Fire- and smoke-resistant (FSK) foil-faced batts use a facing that affords a fire propagation resistance index of 25 or less, and a smoke developed index of 50 or less when tested in accordance with ASTM E84. Such batts typically require a nominal fiber index of about 16.5±about 2 units or a nominal fiber diameter of about 18±about 2 ht, and nominal loss on ignition of 4.5±0.5%.

In one illustrative variation, a standard foil-faced batt and a fire- and smoke-resistant (FSK) foil-faced batt of commercial building insulation has an R-value of about 11, a nominal thickness of about 3.5 in, and a nominal weight of about 0.1 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1420 lbs/ft². In another variation, a standard foil-faced batt and a fire- and smoke-resistant (FSK) foil-faced batt of commercial building insulation has an R-value of about 13, a nominal thickness of about 3.5 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2316 lbs/ft². In another variation, a standard foil-faced batt and a fire- and smoke-resistant (FSK) foil-faced batt of commercial building insulation has an R-value of about 19, a nominal thickness of about 6.25 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2340 lbs/ft². In another variation, a standard foil-faced batt and a fire- and smoke-resistant (FSK) foil-faced batt of commercial building insulation has an R-value of about 30, a nominal thickness of about 10 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3631 lbs/ft². In another variation, a standard foil-faced batt and a fire- and smoke-resistant (FSK) foil-faced batt of commercial building insulation has an R-value of about 38, a nominal thickness of abut 12 in, and a nominal weight of about 0.5 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4957 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by rigid plenum liner. Rigid plenum liner is a thermal and acoustical insulation product including glass fibers preformed into heavy density boards bonded with a thermoset binder. This product has a black top layer of fiberglass, and a black overspray applied to the airstream surface to provide a tough finish with a dark surface. Rigid plenum liner may be used as an interior insulation material for heating, ventilating, and air conditioning plenums and sheet metal ducts. It offers a combination of sound absorption, low thermal conductivity, and minimal air surface friction for systems operating at temperatures up to about 250° F. and velocities up to about 5000 fpm. Thermal conductivity and acoustical properties for rigid plenum liner are determined in accordance with ASTM C 177 and C423 (Type A Mounting), respectively. Thickness and/or density are determined in accordance with ASTM C 167. Rigid plenum liner typically requires a nominal fiber diameter of about 33±about 2 ht, and a nominal loss on ignition of about 15±about 2%.

In one illustrative variation, rigid plenum liner has a nominal density of about 3 lbs/ft³, a nominal thickness of about 1 in, a thermal conductance of about 0.23, a thermal resistance of about 4.3, and a noise reduction coefficient of about 0.65. In another variation, rigid plenum liner has a nominal density of about 3 lbs/ft³, a nominal thickness of about 1.5 in, a thermal conductance of about 0.15, a thermal resistance of about 6.5, and a noise reduction coefficient of about 0.85. In another variation, rigid plenum liner has a nominal density of about 3 lbs/ft³, a nominal thickness of about 2 in, a thermal conductance of about 0.11, a thermal resistance of about 8.7, and a noise reduction coefficient of about 0.95.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by textile duct liner insulation. Textile duct liner insulation is a flexible edge-coated, mat-faced insulation including glass fibers bonded with a thermoset binder. This product is faced with a tightly bonded mat, providing the air stream side with a smooth, tough surface that resists damage during installation and operation. Textile duct liner may be used as an interior insulation material for sheet metal ducts in heating, ventilating, and air conditioning applications. It offers a combination of sound absorption, low thermal conductivity, and minimal air surface friction for systems operating at temperatures up to about 250° F. and velocities up to about 6000 fpm. Thermal and acoustical properties for textile duct liner are determined in accordance with ASTM C 177 and C423 (Type A Mounting), respectively. Thickness and/or density are determined in accordance with ASTM C 167.

In one illustrative variation, textile duct liner has a nominal density of about 1.5 lbs/ft³, a nominal thickness of about 1 in, a thermal conductance of about 0.25, a thermal resistance of about 4.0, and a noise reduction coefficient of about 0.70. In another variation, textile duct liner has a nominal density of about 1.5 lbs/ft³, a nominal thickness of about 1.5 in, a thermal conductance of about 0.17, a thermal resistance of about 6.0, and a noise reduction coefficient of about 0.80. In another variation, textile duct liner has a nominal density of about 1.5 lbs/ft³, a nominal thickness of about 2 in, a thermal conductance of about 0.13, a thermal resistance of about 8.0, and a noise reduction coefficient of about 0.90.

In another illustrative variation, textile duct liner has a nominal density of about 2 lbs/ft³, a nominal thickness of about 0.5 in, a thermal conductance of about 0.48, a thermal resistance of about 2.1, and a noise reduction coefficient of about 0.45. In another variation, textile duct liner has a nominal density of about 2 lbs/ft³, a nominal thickness of about 1 in, a thermal conductance of about 0.24, a thermal resistance of about 4.2, and a noise reduction coefficient of about 0.70. In another variation, textile duct liner has a nominal density of about 2 lbs/ft³, a nominal thickness of about 1.5 in, a thermal conductance of about 0.16, a thermal resistance of about 6.3, and a noise reduction coefficient of about 0.85.

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by exterior foundation insulation board. Exterior foundation insulation board is a uniformly textured, thermal insulating and sound absorbing material including glass fibers preformed into boards that are bonded with a thermoset binder. This product may have drainage capability parallel to the thickness of the board and sufficient compressive strength to maintain the drainage capability after backloading with soil. Thermal properties for exterior foundation insulation board are determined in accordance with ASTM C 653 in accordance with ASTM C 665. Thickness and/or density are determined in accordance with ASTM C 167. Exterior foundation insulation board typically requires a nominal fiber diameter of about 37±about 2 ht, and a nominal loss on ignition of about 17±about 2%.

In one illustrative variation, exterior foundation insulation board has an R-value of about 3, a nominal thickness of about 0.75 in, and a nominal weight of about 0.3 lbs/ft², e.g., in some embodiments the nominal weight can be about 0.2500 lbs/ft². In another variation, exterior foundation insulation board has an R-value of about 5, a nominal thickness of about 1.2 in, and a nominal weight of about 0.4 lbs/ft², e.g., in some embodiments the nominal weight can be about 0.3958 lbs/ft². In another variation, exterior foundation insulation board has an R-value of about 10, a nominal thickness of about 2.4 in, and a nominal weight of about 0.8 lbs/ft², e.g., in some embodiments the nominal weight can be about 0.7917 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by marine hull insulation board. Marine hull insulation board is a skidded smooth, resilient, high temperature thermal insulating and sound absorbing material including glass fibers that are bonded with a high temperature thermoset binder. The thermoset binder minimizes exothermic temperature rise and protects against punking and fusing of the product when applied at maximum operating temperature. The binder content of this product is related to maintaining the product's rated temperature resistance and reducing the smoke and off-gassing generated during the decomposition of the binder during product heat-up. This product may be used for high temperature applications for hot surface temperatures up to about 850° F. with no heat-up cycle required. Thickness and/or density are determined in accordance with ASTM C 167. Marine hull insulation board typically requires a nominal fiber diameter of about 27±about 3 ht, and a nominal loss on ignition of about 7±about 1%.

In one illustrative variation, marine hull board insulation has a nominal density of about 3 lbs/ft³, a nominal thickness of about 1 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal density can be about 2.8 lbs/ft³ and the nominal weight can be about 0.2312 lbs/ft². In another variation, marine hull board insulation has a nominal density of about 3 lbs/ft³, a nominal thickness of about 2 in, and a nominal weight of about 0.5 lbs/ft², e.g., in such embodiments the nominal density can be about 2.8 lbs/ft³ and the nominal weight can be about 0.4625 lbs/ft². In another variation, marine hull board insulation has a nominal density of about 3 lbs/ft³, a nominal thickness of about 3 in, and a nominal weight of about 0.7 lbs/ft², e.g., in such embodiments the nominal density can be about 2.8 lbs/ft³ and the nominal weight can be about 0.7000 lbs/ft². In another variation, marine hull board insulation has a nominal density of about 3 lbs/ft³, a nominal thickness of about 4 in, and a nominal weight of about 0.9 lbs/ft², e.g., in such embodiments the nominal density can be about 2.8 lbs/ft³ and the nominal weight can be about 0.9333 lbs/ft².

In another illustrative embodiment, the cured binders described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by Canadian commercial building insulation batts. Canadian commercial building insulation is an unfaced, semi-rigid batt insulation prepared for the Canadian market. This product is a uniformly textured, resilient, thermal insulating and sound absorbing material including glass fibers that are bonded with a high temperature thermoset binder. Canadian commercial building insulation may be used in wall panels, roof cavities, and between metal studs in pre-engineered metal buildings, and other types of commercial building applications. This product has sufficient tensile strength, bond strength, and rigidity for normal handling by a fabricator or contractor. Thermal properties for Canadian commercial building insulation are determined in accordance with ASTM C 653 in accordance with ASTM C 665. Thickness and/or density are determined in accordance with ASTM C 167. Canadian commercial building insulation typically requires a nominal fiber diameter of about 18±about 2 ht, and a nominal loss on ignition of about 4.5±about 0.5%.

In one illustrative variation, a batt of Canadian commercial building insulation has an R-value of about 8, a nominal thickness of about 2 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.1833 lbs/ft². In another variation, a batt of Canadian commercial building insulation has an R-value of about 10, a nominal thickness of about 2.5 in, and a nominal weight of about 0.2 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2292 lbs/ft². In another variation, a batt of Canadian commercial building insulation has an R-value of about 12, a nominal thickness of about 3 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.2750 lbs/ft². In another variation, a batt of Canadian commercial building insulation has an R-value of about 14, a nominal thickness of about 3.5 in, and a nominal weight of about 0.3 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3208 lbs/ft². In another variation, a batt of Canadian commercial building insulation has an R-value of about 16, a nominal thickness of about 4 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.3667 lbs/ft². In another variation, a batt of Canadian commercial building insulation has an R-value of about 18, a nominal thickness of about 4.5 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4125 lbs/ft². In another variation, a batt of Canadian commercial building insulation has an R-value of about 20, a nominal thickness of about 5 in, and a nominal weight of about 0.4 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.4583 lbs/ft². In another variation, a batt of Canadian commercial building insulation has an R-value of about 22, a nominal thickness of about 5.5 in, and a nominal weight of about 0.5 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.5042 lbs/ft². In another variation, a batt of Canadian commercial building insulation has an R-value of about 24, a nominal thickness of about 6 in, and a nominal weight of about 0.6 lbs/ft², e.g., in such embodiments the nominal weight can be about 0.5500 lbs/ft².

With respect to making binders that are water-resistant thermoset binders when cured, it should be appreciated that the ratio of the number of molar equivalents of acid salt groups present on the polycarboxylic acid reactant to the number of molar equivalents of hydroxyl groups present on the carbohydrate reactant may be in the range from about 0.04:1 to about 0.15:1. After curing, these formulations result in a water-resistant thermoset binder. In one illustrative variation, the number of molar equivalents of hydroxyl groups present on the carbohydrate reactant is about twenty five-fold greater than the number of molar equivalents of acid salt groups present on the polycarboxylic acid reactant. In another variation, the number of molar equivalents of hydroxyl groups present on the carbohydrate reactant is about ten-fold greater than the number of molar equivalents of acid salt groups present on the polycarboxylic acid reactant. In yet another variation, the number of molar equivalents of hydroxyl groups present on the carbohydrate reactant is about six-fold greater than the number of molar equivalents of acid salt groups present on the polycarboxylic acid reactant.

In other illustrative embodiments of the present invention, a binder that is already cured can be disposed on a material to be bound. As indicated above, most cured binders of the present invention will typically contain water-insoluble melanoidins. Accordingly, these binders will also be water-resistant thermoset binders.

As discussed below, various additives can be incorporated into the binder composition. These additives may give the binders of the present invention additional desirable characteristics. For example, the binder may include a silicon-containing coupling agent. Many silicon-containing coupling agents are commercially available from the Dow-Corning Corporation, Petrarch Systems, and from the General Electric Company. Illustratively, the silicon-containing coupling agent includes compounds such as silylethers and alkylsilyl ethers, each of which may be optionally substituted, such as with halogen, alkoxy, amino, and the like. In one variation, the silicon-containing compound is an amino-substituted silane, such as, gamma-aminopropyltriethoxy silane (General Electric Silicones, SILQUEST A-1101; Wilton, Conn.; USA). In another variation, the silicon-containing compound is an amino-substituted silane, for example, aminoethylaminopropyltrimethoxy silane (Dow Z-6020; Dow Chemical, Midland, Mich.; USA). In another variation, the silicon-containing compound is gamma-glycidoxypropyltrimethoxysilane (General Electric Silicones, SILQUEST A-187). In yet another variation, the silicon-containing compound is an n-propylamine silane (Creanova (formerly Huls America) HYDROSIL 2627; Creanova; Somerset, N.J.; U.S.A.).

The silicon-containing coupling agents are typically present in the binder in the range from about 0.1 percent to about 1 percent by weight based upon the dissolved binder solids (i.e., about 0.1 percent to about 1 percent based upon the weight of the solids added to the aqueous solution). In one application, one or more of these silicon-containing compounds can be added to the aqueous uncured binder. The binder is then applied to the material to be bound. Thereafter, the binder may be cured if desired. These silicon-containing compounds enhance the ability of the binder to adhere to the matter the binder is disposed on, such as glass fibers. Enhancing the binder's ability to adhere to the matter improves, for example, its ability to produce or promote cohesion in non-assembled or loosely-assembled substances.

A binder that includes a silicon-containing coupling agent can be prepared from a polycarboxylic acid reactant and a carbohydrate reactant, the latter having reducing sugar, which reactants are added as solids, mixed into and dissolved in water, and then treated with aqueous amine base (to neutralize the polycarboxylic acid reactant) and a silicon-containing coupling agent to generate an aqueous solution about 3-50 weight percent in each of a polycarboxylic acid reactant and a carbohydrate reactant. In one illustrative variation, a binder that includes a silicon-containing coupling agent can be prepared by admixing about 3 weight percent to about 50 weight percent aqueous solution of a polycarboxylic acid reactant, already neutralized with an amine base or neutralized in situ, with about 3-50 weight percent aqueous solution of a carbohydrate reactant having reducing sugar, and an effective amount of a silicon-containing coupling agent.

In another illustrative embodiment, a binder of the present invention may include one or more corrosion inhibitors. These corrosion inhibitors may prevent or inhibit the eating or wearing away of a substance, such as metal, caused by chemical decomposition brought about by an acid. When a corrosion inhibitor is included in a binder of the present invention, the binder's corrosivity is decreased as compared to the corrosivity of the binder without the inhibitor present. In another embodiment, these corrosion inhibitors can be utilized to decrease the corrosivity of the glass fiber-containing compositions described herein. Illustratively, corrosion inhibitors may include one or more of the following, a dedusting oil, a monoammonium phosphate, sodium metasilicate pentahydrate, melamine, tin(II)oxalate, and/or methylhydrogen silicone fluid emulsion. When included in a binder of the present invention, corrosion inhibitors are typically present in the binder in the range from about 0.5 percent to about 2 percent by weight based upon the dissolved binder solids.

By following the disclosed guidelines, one of ordinary skill in the art will be able to vary the concentrations of the reactants of the aqueous binder to produce a wide range of binder compositions. In particular, aqueous binder compositions can be formulated to have an alkaline pH. For example, a pH in the range from greater than or equal to about 7 to less than or equal to about 10. Examples of the binder reactants that can be manipulated include (i) the polycarboxylic acid reactant, (ii) the amine base, (iii) the carbohydrate reactant, (iv) the non-carbohydrate polyhydroxy reactant, (v) the silicon-containing coupling agent, and (vi) the corrosion inhibitor compounds. Having the pH of the aqueous binders (e.g., uncured binders) of the present invention in the alkaline range inhibits the corrosion of materials the binder comes in contact with, such as machines used in the manufacturing process (e.g., in manufacturing fiberglass). Note this is especially true when the corrosivity of acidic binders is compared to binders of the present invention. Accordingly, the “life span” of the machinery increases while the cost of maintaining these machines decreases. Furthermore, standard equipment can be used with the binders of the present invention, rather than having to utilize relatively corrosive resistant machine components that come into contact with acidic binders, such as stainless steel components. Therefore, the binders disclosed herein decrease the cost of manufacturing bound materials.

The following examples illustrate specific embodiments in further detail. These examples are provided for illustrative purposes only and should not be construed as limiting the invention or the inventive concept to any particular physical configuration in any way. For instance, separate aqueous solutions of the polycarboxylic acid ammonium salt reactant and the reducing-sugar carbohydrate reactant the weight percents of each of which fall within the range from about 3-50 weight percent can be admixed to prepare the binders and the bonded materials of the present invention. Further, aqueous solutions including the polycarboxylic acid ammonium salt reactant and the reducing-sugar carbohydrate reactant the weight percents of each of which fall outside the range of about 3-50 weight percent can be used to prepare the binders and the bonded materials of the present invention. In addition, a primary amine salt or a secondary amine salt of a polycarboxylic acid may be used as the polycarboxylic acid ammonium salt reactant to prepare the binders and the bonded materials of the present invention.

Example 1 Preparation of Aqueous Triammonium Citrate-Dextrose Binders

Aqueous triammonium citrate-dextrose binders were prepared according to the following procedure: Aqueous solutions (25%) of triammonium citrate (81.9 g citric acid, 203.7 g water, and 114.4 g of a 19% percent solution of ammonia) and dextrose monohydrate (50.0 g of dextrose monohydrate in 150.0 g water) were combined at room temperature in the following proportions by volume: 1:24, 1:12, 1:8, 1:6, 1:5, 1:4, and 1:3, where the relative volume of triammonium citrate is listed as “1.” For example, 10 mL of aqueous triammonium citrate mixed with 50 mL of aqueous dextrose monohydrate afforded a “1:5” solution, wherein the mass ratio of triammonium citrate to dextrose monohydrate is about 1:5, the molar ratio of triammonium citrate to dextrose monohydrate is about 1:6, and the ratio of the number of molar equivalents of acid salt groups, present on triammonium citrate, to the number of molar equivalents of hydroxyl groups, present on dextrose monohydrate, is about 0.10:1. The resulting solutions were stirred at room temperature for several minutes, at which time 2-g samples were removed and thermally cured as described in Example 2.

Example 2 Preparation of Cured Triammonium Citrate-Dextrose Binder Samples from Aqueous Triammonium Citrate-Dextrose Binders

2-g samples of each binder, as prepared in Example 1, were placed onto each of three individual 1-g aluminum bake-out pans. Each binder was then subjected to the following three conventional bake-out/cure conditions in pre-heated, thermostatted convection ovens in order to produce the corresponding cured binder sample: 15 minutes at 400° F., 30 minutes at 350° F., and 30 minutes at 300° F.

Example 3 Testing/Evaluation of Cured Triammonium Citrate-Dextrose Binder Samples Produced from Aqueous Triammonium Citrate-Dextrose Binders

Wet strength was determined for each cured triammonium citrate-dextrose binder sample, as prepared in Example 2, by the extent to which a cured binder sample appeared to remain intact and resist dissolution, following addition of water to the aluminum bake-out pan and subsequent standing at room temperature. Wet strength was noted as Dissolved (for no wet strength), Partially Dissolved (for minimal wet strength), Softened (for intermediate wet strength), or Impervious (for high wet strength, water-insoluble). The color of the water resulting from its contact with cured ammonium citrate-dextrose binder samples was also determined. Table 1 below shows illustrative examples of triammonium citrate-dextrose binders prepared according to Example 1, curing conditions therefor according to Example 2, and testing and evaluation results according to Example 3.

Example 4 Elemental Analysis of Cured Triammonium Citrate-Dextrose (1:6) Binder Samples

Elemental analyses for carbon, hydrogen, and nitrogen (i.e., C, H, N) were conducted on 5-g samples of 15% triammonium citrate-dextrose (1:6) binder, prepared as described in Example 1 and cured as described below, which 0.75-g cured samples included a molar ratio of triammonium citrate to dextrose monohydrate of about 1:6. Binder samples were cured as a function of temperature and time as follows: 300° F. for 1 hour; 350° F. for 0.5 hour; and 400° F. for 0.33 hour. Elemental analyses were conducted at Galbraith Laboratories, Inc. in Knoxville, Tenn. As shown in Table 2, elemental analysis revealed an increase in the C:N ratio as a function of increasing temperature over the range from 300° F. to 350° F., which results are consistent with a melanoidin-containing binder having been prepared. Further, an increase in the C:H ratio as a function of increasing temperature is also shown in Table 2, which results are consistent with dehydration, a process known to occur during formation of melanoidins, occurring during binder cure.

Example 5 Preparation of Ammonium Polycarboxylate-Sugar Binders Used to Construct Glass Bead Shell Bones, Glass Fiber-Containing Mats, and Wood Fiber Board Compositions

Aqueous triammonium citrate-dextrose (1:6) binders, which binders were used to construct glass bead shell bones and glass fiber-containing mats, were prepared by the following general procedure: Powdered dextrose monohydrate (915 g) and powdered anhydrous citric acid (152.5 g) were combined in a 1-gallon reaction vessel to which 880 g of distilled water was added. To this mixture were added 265 g of 19% aqueous ammonia with agitation, and agitation was continued for several minutes to achieve complete dissolution of solids. To the resulting solution were added 3.3 g of SILQUEST A-1101 silane to produce a pH ˜8-9 solution (using pH paper), which solution contained approximately 50% dissolved dextrose monohydrate and dissolved ammonium citrate solids (as a percentage of total weight of solution); a 2-g sample of this solution, upon thermal curing at 400° F. for 30 minutes, would yield 30% solids (the weight loss being attributed to dehydration during thermoset binder formation). Where a silane other than SILQUEST A-1101 was included in the triammonium citrate-dextrose (1:6) binder, substitutions were made with SILQUEST A-187 Silane, HYDROSIL 2627 Silane, or Z-6020 Silane. When additives were included in the triammonium citrate-dextrose (1:6) binder to produce binder variants, the standard solution was distributed among bottles in 300-g aliquots to which individual additives were then supplied.

The FT-IR spectrum of a dried (uncured) triammonium citrate-dextrose (1:6) binder, which spectrum was obtained as a microscopic thin film from a 10-g sample of a 30% (dissolved binder solids) binder dried in vacuo, is shown in FIG. 3. The FT-IR spectrum of a cured triammonium citrate-dextrose (1:6) Maillard binder, which spectrum was obtained as a microscopic thin film from a 10-g sample of a 30% binder (dissolved binder solids) after curing, is shown in FIG. 4.

When polycarboxylic acids other than citric acid, sugars other than dextrose, and/or additives were used to prepare aqueous ammonium polycarboxylate-sugar binder variants, the same general procedure was used as that described above for preparation of an aqueous triammonium citrate-dextrose (1:6) binder. For ammonium polycarboxylate-sugar binder variants, adjustments were made as necessary to accommodate the inclusion of, for example, a dicarboxylic acid or a polymeric polycarboxylic acid instead of citric acid, or to accommodate the inclusion of, for example, a triose instead of dextrose, or to accommodate the inclusion of, for example, one or more additives. Such adjustments included, for example, adjusting the volume of aqueous ammonia necessary to generate the ammonium salt, adjusting the gram amounts of reactants necessary to achieve a desired molar ratio of ammonium polycarboxylate to sugar, and/or including an additive in a desired weight percent.

Example 6 Preparation/Weathering/Testing of Glass Bead Shell Bone Compositions Prepared with Ammonium Polycarboxylate-Sugar Binders

When evaluated for their dry and “weathered” tensile strength, glass bead-containing shell bone compositions prepared with a given binder provide an indication of the likely tensile strength and the likely durability, respectively, of fiberglass insulation prepared with that particular binder. Predicted durability is based on a shell bone's weathered tensile strength:dry tensile strength ratio. Shell bones were prepared, weathered, and tested as follows:

Preparation Procedure for Shell Bones:

A shell bone mold (Dietert Foundry Testing Equipment; Heated Shell Curing Accessory, Model 366, and Shell Mold Accessory) was set to a desired temperature, generally 425° F., and allowed to heat up for at least one hour. While the shell bone mold was heating, approximately 100 g of an aqueous ammonium polycarboxylate-sugar binder (generally 30% in binder solids) was prepared as described in Example 5. Using a large glass beaker, 727.5 g of glass beads (Quality Ballotini Impact Beads, Spec. AD, US Sieve 70-140, 106-212 micron-#7, from Potters Industries, Inc.) were weighed by difference. The glass beads were poured into a clean and dry mixing bowl, which bowl was mounted onto an electric mixer stand. Approximately 75 g of aqueous ammonium polycarboxylate-sugar binder were obtained, and the binder then poured slowly into the glass beads in the mixing bowl. The electric mixer was then turned on and the glass beads/ammonium polycarboxylate-sugar binder mixture was agitated for one minute. Using a large spatula, the sides of the whisk (mixer) were scraped to remove any clumps of binder, while also scraping the edges wherein the glass beads lay in the bottom of the bowl. The mixer was then turned back on for an additional minute, and then the whisk (mixer) was removed from the unit, followed by removal of the mixing bowl containing the glass beads/ammonium polycarboxylate-sugar binder mixture. Using a large spatula, as much of the binder and glass beads attached to the whisk (mixer) as possible were removed and then stirred into the glass beads/ammonium polycarboxylate-sugar binder mixture in the mixing bowl. The sides of the bowl were then scraped to mix in any excess binder that might have accumulated on the sides. At this point, the glass beads/ammonium polycarboxylate-sugar binder mixture was ready for molding in a shell bone mold.

The slides of the shell bone mold were confirmed to be aligned within the bottom mold platen. Using a large spatula, a glass beads/ammonium polycarboxylate-sugar binder mixture was then quickly added into the three mold cavities within the shell bone mold. The surface of the mixture in each cavity was flattened out, while scraping off the excess mixture to give a uniform surface area to the shell bone. Any inconsistencies or gaps that existed in any of the cavities were filled in with additional glass beads/ammonium polycarboxylate-sugar binder mixture and then flattened out. Once a glass beads/ammonium polycarboxylate-sugar binder mixture was placed into the shell bone cavities, and the mixture was exposed to heat, curing began. As manipulation time can affect test results, e.g., shell bones with two differentially cured layers can be produced, shell bones were prepared consistently and rapidly. With the shell bone mold filled, the top platen was quickly placed onto the bottom platen. At the same time, or quickly thereafter, measurement of curing time was initiated by means of a stopwatch, during which curing the temperature of the bottom platen ranged from about 400° F. to about 430° F., while the temperature of the top platen ranged from about 440° F. to about 470° F. At seven minutes elapsed time, the top platen was removed and the slides pulled out so that all three shell bones could be removed. The freshly made shell bones were then placed on a wire rack, adjacent to the shell bone mold platen, and allowed to cool to room temperature. Thereafter, each shell bone was labeled and placed individually in a plastic storage bag labeled appropriately. If shell bones could not be tested on the day they were prepared, the shell bone-containing plastic bags were placed in a desiccator unit.

Conditioning (Weathering) Procedure for Shell Bones:

A Blue M humidity chamber was turned on and then set to provide weathering conditions of 90° F. and 90% relative humidity (i.e., 90° F./90% rH). The water tank on the side of the humidity chamber was checked and filled regularly, usually each time it was turned on. The humidity chamber was allowed to reach the specified weathering conditions over a period of at least 4 hours, with a day-long equilibration period being typical. Shell bones to be weathered were loaded quickly (since while the doors are open both the humidity and the temperature decrease), one at a time through the open humidity chamber doors, onto the upper, slotted shelf of the humidity chamber. The time that the shell bones were placed in the humidity chamber was noted, and weathering conducted for a period of 24 hours. Thereafter, the humidity chamber doors were opened and one set of shell bones at a time were quickly removed and placed individually into respective plastic storage bags, being sealed completely. Generally, one to four sets of shell bones at a time were weathered as described above. Weathered shell bones were immediately taken to the Instron room and tested.

Test Procedure for Breaking Shell Bones:

In the Instron room, the shell bone test method was loaded on the 5500 R Instron machine while ensuring that the proper load cell was installed (i.e., Static Load Cell 5 kN), and the machine allowed to warm up for fifteen minutes. During this period of time, shell bone testing grips were verified as being installed on the machine. The load cell was zeroed and balanced, and then one set of shell bones was tested at a time as follows: A shell bone was removed from its plastic storage bag and then weighed. The weight (in grams) was then entered into the computer associated with the Instron machine. The measured thickness of the shell bone (in inches) was then entered, as specimen thickness, three times into the computer associated with the Instron machine. A shell bone specimen was then placed into the grips on the Instron machine, and testing initiated via the keypad on the Instron machine. After removing a shell bone specimen, the measured breaking point was entered into the computer associated with the Instron machine, and testing continued until all shell bones in a set were tested.

Test results are shown in Tables 3-6, which results are mean dry tensile strength (psi), mean weathered tensile strength (psi), and weathered:dry tensile strength ratio.

Example 7 Preparation/Weathering/Testing of Glass Fiber-Containing Mats Prepared with Ammonium Polycarboxylate-Sugar (1:6) Binders

When evaluated for their dry and “weathered” tensile strength, glass fiber-containing mats prepared with a given binder provide an indication of the likely tensile strength and the likely durability, respectively, of fiberglass insulation prepared with that particular binder. Predicted durability is based on a glass fiber mat's “weathered” tensile strength:dry tensile strength ratio. Glass fiber mats were prepared, weathered, and tested as follows:

Preparation Procedure for Glass Fiber-Containing Mats:

A “Deckel box,” 13 inches high×13 inches wide×14 inches deep, was constructed of clear acrylic sheet and attached to a hinged metal frame. Under the Deckel box, as a transition from the box to a 3-inch drain pipe, was installed a system of a perforated plate and coarse metal screen. A woven plastic belt (called a “wire”) was clamped under the Deckel box. For mixing purposes, a 5-gallon bucket equipped with an internal, vertical rib and a high-shear air motor mixer were used. Typically, 4 gallons of water and E-glass (i.e., high-temperature glass) fibers (11 g, 22 g, or 33 g) were mixed for two minutes. A typical E-glass had the following weight percent composition: SiO₂, 52.5%; Na₂O, 0.3%; CaO, 22.5%; MgO, 1.2%; Al₂O₃, 14.5%; FeO/Fe₂O₃, 0.2%; K₂O, 0.2%; and B₂O₃, 8.6%. The drain pipe and transition under the wire had previously been filled with water such that the bottom of the Deckel box was wetted. The aqueous, glass fiber mixture was poured into the Deckel box and agitated vertically with a plate containing forty nine (49) one-inch holes. The slide valve at the bottom of the drain line was opened quickly and the glass fibers collected on the wire. A screen-covered frame, already in place under the wire, facilitated the transfer of the glass fiber sample. The sample was dewatered by passing over an extractor slot with 25-40 inches of water-column suction. One pass was used for an 11-g sample, two passes were used for a 22-g sample, and three passes were used for a 33-g sample. The sample was transferred to a second screen-covered frame and the forming wire removed. The sample was then dried and separated from the screen. Subsequently, the sample was passed over a 3-inch diameter applicator roll rotating in a bath containing an aqueous ammonium polycarboxylate-sugar binder (containing 15% dissolved binder solids, prepared as described in Example 5), wherein the glass fibers were saturated with binder. The excess binder was extracted by passing over the extractor slot again to produce glass fiber-containing mats, which mats were cured at 375° F. for 30 minutes in an oven having up-flow forced convection air.

Conditioning (Weathering) Procedure for Glass Fiber Mats:

Glass fiber-containing mat samples to be conditioned were placed on TEFLON-coated course-weave belt and weighted down to prevent floating. A pair of sample mats was prepared for each ammonium polycarboxylate-sugar binder under evaluation. The mats were conditioned at ambient temperature and humidity in an air-conditioned, but not humidity-controlled room for at least one day. Seven test specimens were cut from each mat using a die with the proper profile; six specimens were cut in one direction and one specimen was cut in a perpendicular direction, with each specimen kept separate. Each specimen was 2 inches wide and narrowed down to 1 inch wide in the mid-section, while being approximately 12 inches long. Three specimens from each mat were placed in a “weathering” chamber at 37-38° C. and 90% relative humidity for 24 hours. The weathered specimens were removed from the chamber and stored in sealable plastic bags, each bag containing a moist paper towel, until immediately before testing.

Test Procedure for Breaking Glass Fiber Mats:

A tensile tester was set up with a crosshead speed of 0.5 inches per minute. The clamp jaws were 2 inches wide and had approximately 1.5-inch grips. Three dry specimens and three weathered specimens were tested from each mat. The dry specimens were used for binder content measurement, as determined by loss on ignition (LOI).

Test results are shown in Table 7, which results are mean % LOT, mean dry tensile strength (lb force), mean weathered tensile strength (lb force), and weathered:dry tensile strength ratio.

Example 8 Preparation of Triammonium Citrate-Dextrose (1:6) Binder/Glass Fiber Compositions: Uncured Blanket and Cured Blanket

Powdered dextrose monohydrate (300 lbs) and powdered anhydrous citric acid (50 lbs) were combined in a 260-gallon tote. Soft water was then added to achieve a volume of 235 gallons. To this mixture were added 9.5 gallons of 19% aqueous ammonia, and the resulting mixture was stirred to achieve complete dissolution of solids. To the resulting solution were added 0.56 lbs of SILQUEST A-1101 silane to produce a solution 15.5% in dissolved dextrose monohydrate and dissolved ammonium citrate solids (as a percentage of total weight of solution); a 2-g sample of this solution, upon thermal curing at 400° F. for 30 minutes, would yield 9.3% solids (the weight loss being attributed to dehydration during thermoset binder formation). The solution was stirred for several minutes before being transported to a binder pump where it was used in the manufacture of glass fiber insulation, specifically, in the formation of material referred to as “wet blanket,” or “ship out” uncured, and “amber blanket,” or cured blanket.

Uncured blanket and cured blanket were prepared using conventional fiberglass manufacturing procedures; such procedures are depicted in FIG. 7 and are described generally below and in U.S. Pat. No. 5,318,990, the disclosure of which is hereby incorporated herein by reference. Typically, a binder is applied to glass fibers as they are being produced and formed into a mat, water is volatilized from the binder, and the high-solids binder-coated fibrous glass mat is heated to cure the binder and thereby produce a finished fibrous glass bat which may be used, for example, as a thermal or acoustical insulation product, a reinforcement for a subsequently produced composite, etc.

A porous mat of fibrous glass was produced by fiberizing molten glass and immediately forming a fibrous glass mat on a moving conveyor. Glass was melted in a tank and supplied to a fiber forming device such as a spinner or a bushing. Fibers of glass were attenuated from the device and then blown generally downwardly within a forming chamber. The glass fibers typically have a diameter from about 2 to about 9 microns and have a length from about 0.25 inch to about 3 inches. Typically, the glass fibers range in diameter from about 3 to about 6 microns, and have a length from about 0.5 inch to about 1.5 inches. The glass fibers were deposited onto a perforated, endless forming conveyor. A binder was applied to the glass fibers, as they were being formed, by means of suitable spray applicators so as to result in a distribution of the binder throughout the formed mat of fibrous glass. The glass fibers, having the uncured binder adhered thereto, were gathered and formed into a mat on the endless conveyor within the forming chamber with the aid of a vacuum drawn through the mat from below the forming conveyor. The residual heat contained in the glass fibers as well as the air flow through the mat caused a majority of the water to volatilize from the mat before it exited the forming chamber. (Water was removed to the extent the uncured binder functioned as a binder; the amount of water to be removed for any particular application can be determined buy one of ordinary skill in the art with routine experimentation)

As the high-solids binder-coated fibrous glass mat emerged from the forming chamber, it expanded vertically due to the resiliency of the glass fibers. The expanded mat was then conveyed to and through a curing oven wherein heated air is passed through the mat to cure the binder. Flights above and below the mat slightly compressed the mat to give the finished product a predetermined thickness and surface finish. As mentioned above, one exemplary way of obtaining a desired thickness is to compress the mat by utilizing the afore-mentioned flights. Since thickness is related to density, a desired density may be achieved by compressing the mat utilizing the afore-mentioned flights. Another exemplary way of obtaining a desired density is by altering the amount of glass fibers per unit volume. Fiber size can be manipulated by adjusting the fiber forming device (e.g., a spinner or a bushing) in a well-known manner to obtain a desired fiber size. Further, binder content can be adjusted by increasing or decreasing the concentration (i.e., the percent solids) of liquid binder, and/or by increasing or decreasing the volume of binder that is sprayed onto glass fibers. Density, fiber size, and/or binder content may be varied to produce a particular insulation product with desired thermal and acoustical properties.

Typically, the curing oven was operated at a temperature over a range from about 350° F. to about 600° F. Generally, the mat resided within the oven for a period of time from about 0.5 minute to about 3 minutes. For the manufacture of conventional thermal or acoustical insulation products, the time ranges from about 0.75 minute to about 1.5 minutes. The fibrous glass having a cured, rigid binder matrix emerged from the oven in the form of a bat which may be compressed for packaging and shipping and which will thereafter substantially recover its as-made vertical dimension when unconstrained. By way of example, a fibrous glass mat which is about 1.25 inches thick as it exits from the forming chamber, will expand to a vertical thickness of about 9 inches in the transfer zone, and will be slightly compressed to a vertical thickness of about 6 inches in the curing oven.

Nominal specifications of the cured blanket product prepared as described above were about 0.09 pounds per square foot weight, about 0.7 pounds per cubic foot density, about 1.5 inch thick, fiber diameter of about 22 hundred thousandths of an inch (5.6 microns), about 11% binder content after curing, and about 0.7% mineral oil content for dedusting (dedusting oil). Curing oven temperature was set at about 460° F. Uncured blanket exited the forming chamber white to off-white in apparent color, whereas cured blanket exited the oven dark brown in apparent color and well bonded.

Example 9 Preparation of Triammonium Citrate-Dextrose (1:6) Binder/Glass Fiber Composition: Air Duct Board

Powdered dextrose monohydrate (1800 lbs) and powdered anhydrous citric acid (300 lbs) were combined in a 2000-gallon mixing tank that contained 743.2 gallons of soft water. To this mixture were added 52.9 gallons of 19% aqueous ammonia under agitation, and agitation was continued for approximately 30 minutes to achieve complete dissolution of solids. To the resulting solution were added 9 lbs of SILQUEST A-1101 silane to produce a pH ˜8 solution (using pH paper), which solution contained approximately 25% dissolved dextrose monohydrate and dissolved ammonium citrate solids (as a percentage of total weight of solution); a 2-g sample of this solution, upon thermal curing at 400° F. for 30 minutes, would yield 15% solids (the weight loss being attributed to dehydration during thermoset binder formation). The solution was stirred for several minutes before being transferred to a binder hold tank from which it was used in the manufacture of glass fiber insulation, specifically, in the formation of a product called “air duct board.”

Air duct board was prepared using conventional fiberglass manufacturing procedures; such procedures are described generally in Example 8. Nominal specifications of the air duct board product were about 0.4 pounds per square foot density, about 4.5 pounds per cubic foot density, at 1 inch thick, with a fiber diameter of about 32 hundred thousandths of an inch (8.1 microns), and a binder content of about 14.3%, with 0.7% mineral oil for dedusting (dedusting oil). Curing oven temperature was set at about 550° F. Product exited the oven dark brown in apparent color and well bonded.

Example 10 Preparation of Triammonium Citrate-Dextrose (1:6) Binder/Glass Fiber Composition: R30 Residential Blanket

Powdered dextrose monohydrate (1200 lbs) and powdered anhydrous citric acid (200 lbs) were combined in a 2000-gallon mixing tank that contained 1104 gallons of soft water. To this mixture were added 42.3 gallons of 19% aqueous ammonia under agitation, and agitation was continued for approximately 30 minutes to achieve complete dissolution of solids. To the resulting solution were added 6 lbs of SILQUEST A-1101 silane to produce a pH ˜8 solution (using pH paper), which solution contained approximately 13.4% dissolved dextrose monohydrate and dissolved ammonium citrate solids (as a percentage of total weight of solution); a 2-g sample of this solution, upon thermal curing at 400° F. for 30 minutes, would yield 8% solids (the weight loss being attributed to dehydration during thermoset binder formation). The solution was stirred for several minutes before being transferred to a binder hold tank from which it was used in the manufacture of residential glass fiber insulation, specifically, in the formation of a product called “R30 residential blanket.”

R30 residential blanket was prepared using conventional fiberglass manufacturing procedures; such procedures are described generally in Example 8. Nominal specifications of the R30 residential blanket product were about 0.4 pound per square foot weight, a target recovery of 10 inches thick at the end of the line, with a fiber diameter of 18 hundred thousandths of an inch (4.6 microns), 3.8% binder content, and 0.7% mineral oil content for dedusting (dedusting oil). Curing oven temperature was set at about 570° F. Product exited the oven brown in apparent color and well bonded.

Example 11 Preparation of Triammonium Citrate-Dextrose (1:6) Binder/Glass Fiber Composition: R19 Residential Blanket

Batch A-1:

Powdered dextrose monohydrate (1200 lbs) and powdered anhydrous citric acid (200 lbs) were combined in a 2000 gallon mixing tank that contained 1104 gallons of soft water. To this mixture were added 35.3 gallons of 19% ammonia under agitation, and agitation was continued for approximately 30 minutes to achieve complete dissolution of solids. To the resulting solution were added 6 lbs of SILQUEST A-1101 silane to produce a pH ˜8 solution (using pH paper), which solution contained about 13.3% dissolved dextrose monohydrate and ammonium citrate solids (as a percentage of total weight of solution); a 2-g sample of this solution, upon thermal curing at 400° F. for 30 minutes, would yield 8% solids (the weight loss being attributed to dehydration during thermoset binder formation). The solution was stirred for several minutes before being transferred to a binder hold tank from which it was used in the manufacture of residential glass fiber insulation, specifically, in the formation of a product called “R19 Residential Blanket.”

R19 Residential Blanket, Batch A-1, was prepared using conventional fiberglass manufacturing procedures; such procedures are described generally in Example 8. Nominal specifications of the R19 Residential Blanket product were about 0.2 pound per square foot weight, 0.2 pound per cubic foot density, a target recovery of 6.5 inches thick at the end of the line, with a fiber diameter of 18 hundred thousandths of an inch (4.6 microns), 3.8% binder content, and 0.7% mineral oil content (for dedusting). Curing oven temperature was set at about 570° F. Product exited the oven brown in apparent color and well bonded.

Batch A-2:

Powdered dextrose monohydrate (1200 lbs) and powdered anhydrous citric acid (200 lbs) were combined in a 2000 gallon mixing tank that contained 558 gallons of soft water. To this mixture were added 35.3 gallons of 19% ammonia under agitation, and agitation was continued for approximately 30 minutes to achieve complete dissolution of solids. To the resulting solution were added 5 lbs of SILQUEST A-1101 silane to produce a pH ˜8 solution (using pH paper), which solution contained about 20.5% dissolved dextrose monohydrate and ammonium citrate solids (as a percentage of total weight of solution); a 2-g sample of this solution, upon thermal curing at 400° F. for 30 minutes, would yield 12% solids (the weight loss being attributed to dehydration during thermoset binder formation). The solution was stirred for several minutes before being transferred to a binder hold tank from which it was used in the manufacture of residential glass fiber insulation, specifically, in the formation of a product called “R19 Residential Blanket.”

R19 Residential Blanket, Batch A-2, was prepared using conventional fiberglass manufacturing procedures; such procedures are described generally in Example 8. Nominal specifications of the R19 Residential Blanket product were about 0.2 pound per square foot weight, about 0.4 pound per cubic foot density, a target recovery of 6.5 inches thick at the end of the line, with a fiber diameter of 18 hundred thousandths of an inch (4.6 microns), 3.8% binder content, and 0.7% mineral oil content (for dedusting). Curing oven temperature was set at about 570° F. Product exited the oven brown in apparent color and well bonded.

Batch B:

Powdered dextrose monohydrate (300 lbs) and powdered anhydrous citric acid (50 lbs) were combined in a 260 gallon International Bulk Container (IBC) that already contained 167 gallons of distilled water. To this mixture were added 10.6 gallons of 19% ammonia under agitation, and agitation was continued for approximately 30 minutes to achieve complete dissolution of solids. To the resulting solution were added 1.5 lbs of SILQUEST A-1101 silane to produce a pH ˜8 solution (using pH paper), which solution contained approximately 20.1% dissolved dextrose monohydrate and ammonium citrate solids (as a percentage of total weight of solution); a 2-g sample of this solution, upon thermal curing at 400° F. for 30 minutes, would yield 12% solids (the weight loss being attributed to dehydration during thermoset binder formation). The IBC containing the aqueous binder was transferred to an area at which location the binder was pumped into the binder spray rings in the forming hood, diluted thereinto with distilled water, and then used in the manufacture of residential glass fiber insulation, specifically, in the formation of a product called “R19 Residential Blanket.”

R19 Residential Blanket, Batch B, was prepared using conventional fiberglass manufacturing procedures; such procedures are described generally in Example 8. Nominal specifications of the R19 Residential Blanket product made were about 0.2 pound per square foot weight, and about 0.4 pound per cubic foot density, a target recovery of 6.5 inches thick at the end of the line, with a fiber diameter of 18 hundred thousandths of an inch (4.6 microns), 3.8% binder content, and 0.7% mineral oil content (for dedusting). Curing oven temperature was set at about 570° F. Product exited the oven brown in apparent color and well bonded.

Batch C:

Powdered dextrose monohydrate (300 lbs) and powdered anhydrous citric acid (50 lbs) were combined in a 260 gallon International Bulk Container (IBC) that already contained 167 gallons of distilled water. To this mixture were added 10.6 gallons of 19% ammonia under agitation, and agitation was continued for about 30 minutes to achieve complete dissolution of solids. To the resulting solution were added 1.5 lbs of SILQUEST A-1101 silane followed by 1.80 gallons of the methylhydrogen emulsion BS 1040 (manufactured by the Wacker Chemical Corporation) to produce a pH ˜8 solution (using pH paper), which solution contained approximately 20.2% dissolved dextrose monohydrate and ammonium citrate solids (as a percentage of total weight of solution); a 2-g sample of this solution, upon thermal curing at 400° F. for 30 minutes, would yield 12% solids (the weight loss being attributed to dehydration during thermoset binder formation). The IBC containing the aqueous binder was transferred to an area at which location the binder was pumped into the binder spray rings in the forming hood, diluted thereinto with distilled water, and then used in the manufacture of residential glass fiber insulation, specifically, in the formation of a product called “R19 Residential Blanket.”

R19 Residential Blanket, Batch C, was prepared using conventional fiberglass manufacturing procedures; such procedures are described generally in Example 8. Nominal specifications of the R19 Residential Blanket product made was about 0.2 pound per square foot density, about 0.4 pound per cubic foot weight, a target recovery of 6.5 inches thick at the end of the line, with a fiber diameter of 18 hundred thousandths of an inch (4.6 microns), 3.8% binder content, and 0.7% mineral oil content (for dedusting). Curing oven temperature was set at about 570° F. Product exited the oven brown in apparent color and well bonded.

Batch D:

Powdered dextrose monohydrate (300 lbs) and powdered anhydrous citric acid (50 lbs) were combined in a 260 gallon International Bulk Container (IBC) that already contained 167 gallons of distilled water. To this mixture were added 10.6 gallons of 19% ammonia under agitation, and agitation was continued for approximately 30 minutes to achieve complete dissolution of solids. To the resulting solution were added 1.5 lbs of SILQUEST A-1101 silane followed by 22 lbs of the clay product Bentalite L10 (manufactured by Southern Clay Products) to produce a pH ˜8 solution (using pH paper), which solution contained about 21.0% dissolved dextrose monohydrate and ammonium citrate solids (as a percentage of total weight of solution); a 2-g sample of this solution, upon thermal curing at 400° F. for 30 minutes, would yield 12.6% solids (the weight loss being attributed to dehydration during thermoset binder formation). The IBC containing the aqueous Maillard binder was transferred to an area at which location the binder was pumped into the binder spray rings in the forming hood, diluted thereinto with distilled water, and then used in the manufacture of residential glass fiber insulation, specifically, in the formation of a product called “R19 Residential Blanket.”

R19 Residential Blanket, Batch D, was prepared using conventional fiberglass manufacturing procedures; such procedures are described generally in Example 8. Nominal specifications of the R19 Residential Blanket product made that day were about 0.2 pound per square foot weight, about 0.4 pound per cubic foot density, a target recovery of 6.5 inches thick at the end of the line, with a fiber diameter of 18 hundred thousandths of an inch (4.6 microns), 3.8% binder content, and 0.7% mineral oil content (for dedusting). Curing oven temperature was set at about 570° F. Product exited the oven brown in apparent color and well bonded.

Example 12 Preparation of Triammonium Citrate-Dextrose (1:6) Binder/Glass Fiber Composition: Pipe Insulation-Uncured

Powdered dextrose monohydrate (1200 lbs) and powdered anhydrous citric acid (200 lbs) were combined in a 2000-gallon mixing tank that contained 215 gallons of soft water. To this mixture were added 42.3 gallons of 19% aqueous ammonia under agitation, and agitation was continued for approximately 30 minutes to achieve complete dissolution of solids. To the resulting solution were added 6 lbs of SILQUEST A-1101 silane to produce a pH ˜8 solution (using pH paper), which solution contained approximately 41.7% dissolved dextrose monohydrate and dissolved ammonium citrate solids (as a percentage of total weight of solution); a 2-g sample of this solution, upon thermal curing at 400° F. for 30 minutes, would yield 25% solids (the weight loss being attributed to dehydration during thermoset binder formation). The solution was stirred for several minutes before being transferred to a binder hold tank from which it was used in the manufacture of glass fiber insulation, specifically, in the formation of a product called “pipe insulation-uncured.”

Pipe insulation-uncured was prepared using conventional fiberglass manufacturing procedures; such procedures are described generally in Example 8. Nominal specifications of the pipe insulation uncured product were about 0.07 pound per square foot weight, about 0.85 pound per cubic foot density, an estimated thickness of 1 inch, a fiber diameter of 30 hundred thousandths of an inch (7.6 microns), and a binder content of 7% when cured. Pipe insulation-uncured was transported to a pipe insulation-forming area, where it was cast into cylindrical shells, with 6-inch walls and a 3-inch diameter hole and 4-pound per cubic foot density, to be used as pipe insulation. These shells were cured with the curing oven set at approximately 450° F. to produce dark brown, well-bonded pipe insulation product. Shells cured at higher temperatures exhibited punking and could not be used further for testing.

Example 13 Preparation of Triammonium Citrate-Dextrose (1:6) Binder/Glass Fiber Composition: ET Blanket (Range Insulation)

Powdered dextrose monohydrate (74 lbs) and powdered anhydrous citric acid (12 lbs) were combined in a 2000-gallon mixing tank that contained 390 gallons of soft water. To this mixture were added 2.6 gallons of 19% aqueous ammonia under agitation, and agitation was continued for approximately 30 minutes to achieve complete dissolution of solids. To the resulting solution were added 0.37 lbs of SILQUEST A-1101 silane to produce a pH ˜8 solution (using pH paper), which solution contained approximately 2.65% dissolved dextrose monohydrate and dissolved ammonium citrate solids (as a percentage of total weight of solution); a 2-g sample of this solution, upon thermal curing at 400° F. for 30 minutes, would yield 1.6% solids (the weight loss being attributed to dehydration during thermoset binder formation). The solution was stirred for several minutes before being transferred to a binder hold tank from which it was used in the manufacture of glass fiber insulation, specifically, in the formation of a product called “ET Blanket (range insulation).”

ET Blanket (range insulation) was prepared using conventional fiberglass manufacturing procedures; such procedures are described generally in Example 8. Nominal specifications of the ET Blanket (range insulation) product were about 0.298 pound per square foot weight, about 1.10 pound per cubic foot density, a target recovery of 3.25 inches thick after packaging, with a fiber diameter of 22 hundred thousandths of an inch (5.6 microns), two set points of 1.5% and 3.0% binder content, respectively. Curing oven temperature was set at about 450° F. Product exited the oven light brown in apparent color and reasonably bonded.

Example 14 Preparation of Triammonium Citrate-Dextrose (1:6) Binder/Glass Fiber Composition: Flexible Duct Media

Powdered dextrose monohydrate 3000 lbs) and powdered anhydrous citric acid (500 lbs) were combined in a 2000-gallon mixing tank that contained 390 gallons of soft water. To this mixture were added 106.6 gallons of 19% aqueous ammonia under agitation, and agitation was continued for approximately 30 minutes to achieve complete dissolution of solids. To the resulting solution were added 15 lbs of SILQUEST A-1101 silane. This produced a solution that contained approximately 39.3% dissolved dextrose monohydrate and dissolved ammonium citrate solids (as a percentage of total weight of solution); a 2-g sample of this solution, upon thermal curing at 400° F. for 30 minutes, would yield 23.6% solids (the weight loss being attributed to dehydration during thermoset binder formation). The solution was stirred for several hours before being transferred to a binder hold tank from which it was used in the manufacture of glass fiber insulation, specifically, in the formation of a product called “flexible duct media.”

Flexible duct media was prepared using conventional fiberglass manufacturing procedures; such procedures are described generally in Example 8. Nominal specifications of the flexible duct media product were about 0.115 pound per square foot weight, about 0.690 pound per cubic foot density, a target recovery of 2 inches thick after packaging, with a fiber diameter of 18 hundred thousandths of an inch (4.6 microns), with set points of 5.45%, 11.4%, and 14.25% binder content respectively, and 0.7% mineral oil content for dedusting (dedusting oil). Curing oven temperature was set at about 450° F. Product exited the oven brown in apparent color and well bonded.

Example 15 Testing/Evaluation of Triammonium Citrate-Dextrose (1:6) Binder/Glass Fiber Compositions

The triammonium citrate-dextrose (1:6) binder/glass fiber compositions from Examples 8-12, i.e., cured blanket, air duct board, R30 residential blanket, R19 residential blanket, and pipe insulation-uncured, were tested versus a corresponding phenol-formaldehyde (PF) binder/glass fiber composition for one or more of the following: product emissions, density, loss on ignition, thickness recovery, dust, tensile strength, parting strength, durability of parting strength, bond strength, water absorption, hot surface performance, corrosivity on steel, flexural rigidity, stiffness-rigidity, compressive resistance, conditioned compressive resistance, compressive modulus, conditioned compressive modulus, and smoke development on ignition. The results of these tests are shown in Tables 8-13. Also determined were the gaseous compounds produced during pyrolysis of cured blanket from Example 8, and the gaseous compounds produced during thermal curing of pipe insulation uncured from Example 12; these testing results are shown in Tables 14-15. Hot surface performance for cured pipe insulation is shown in FIG. 5 and FIG. 6. Specific tests conducted and conditions for performing these tests are as follows:

Product Emissions Testing

Product emissions for cured blanket from Example 8 and air duct board from Example 9 were determined in accordance with AQS Greenguard Testing procedures. The insulation products were monitored for emissions of total volatile organic compounds (TVOCs), formaldehyde, total selected aldehydes in accordance with ASTM D5116 (“Standard Guide for Small-Scale Environmental Chamber Determinations of Organic Emissions from Indoor Materials/Products”), the United States Environmental Protection Agency (USEPA), and the State of Washington IAQ Specification of January, 1994. The emission data were collected over a one-week exposure period and the resultant air concentrations were determined for each of the aforementioned substances. Air concentration predictions were computer monitored based on the State of Washington requirements, which include a standard room loading and ASHRAE Standard 62-1999 ventilation conditions. Product loading is based on standard wall usage of 28.1 m² in a 32 m³ room.

Emissions Testing—Selected Aldehydes

The insulation products were tested in a small-sized environmental chamber 0.0855 m³ in volume with the chemical emissions analytically measured. Emission of selected aldehydes, including formaldehyde, were measured following ASTM D5197 (“Standard Test Method for Determination of Formaldehyde and Other Carbonyl Compounds in Air (Active Sampler Methodology)) using high performance liquid chromatography (HPLC). Solid sorbent cartridges with 2,4-dinitrophenylhydrazine (DNPH) were used to collect formaldehyde and other low-molecular weight carbonyl compounds in the chamber air. The DNPH reagent in the cartridge reacted with collected carbonyl compounds to form the stable hydrazone derivatives retained by the cartridge. The hydrazone derivatives were eluted from a cartridge with HPLC-grade acetonitrile. An aliquot of the sample was analyzed for low-molecular weight aldehyde hydrazone derivatives using reverse-phase high-performance liquid chromatography (HPLC) with UV detection. The absorbances of the derivatives were measured at 360 nm. The mass responses of the resulting peaks were determined using multi-point calibration curves prepared from standard solutions of the hydrazone derivatives. Measurements are reported to a quantifiable level of 0.2 μg based on a standard air volume collection of 45 L.

Emissions Testing—Volatile Organic Compounds (VOC)

VOC measurements were made using gas chromatography with mass spectrometric detection (GC/MS). Chamber air was collected onto a solid sorbent which was then thermally desorbed into the GC/MS. The sorbent collection technique, separation, and detection analysis methodology has been adapted from techniques presented by the USEPA and other researchers. The technique follows USEPA Method 1P-1B and is generally applicable to C₅-C₁₆ organic chemicals with a boiling point ranging from 35° C. to 250° C. Measurements are reported to a quantifiable level of 0.4 μg based on a standard air volume collection of 18 L. Individual VOCs were separated and detected by GC/MS. The total VOC measurements were made by adding all individual VOC responses obtained by the mass spectrometer and calibrating the total mass relative to toluene.

Emissions Testing—Air Concentration Determinations

Emission rates of formaldehyde, total aldehydes, and TVOC were used in a computer exposure model to determine the potential air concentrations of the substances. The computer model used the measured emission rate changes over the one-week time period to determine the change in air concentrations that would accordingly occur. The model measurements were made with the following assumptions: air with open office areas in the building is well-mixed at the breathing level zone of the occupied space; environmental conditions are maintained at 50% relative humidity and 73° F. (23° C.); there are no additional sources of these substances; and there are no sinks or potential re-emitting sources within the space for these substances. The USEPA's Indoor Air Exposure Model, Version 2.0, was specifically modified to accommodate this product and chemicals of interest. Ventilation and occupancy parameters were provided in ASHRAE Standard 62-1999.

Density

The density of cured blanket from Example 8 was determined in accordance with internal test method PTL-1, “Test Method for Density and Thickness of Blanket or Batt Thermal Insulation,” which test method is virtually identical to ASTM C 167. The density of air duct board from Example 9 was determined in accordance with internal test method PTL-3, “Test Procedure for Density Preformed Block-Type Thermal Insulation,” which test method is virtually identical to ASTM C 303.

Loss on Ignition (LOI)

The loss on ignition for cured blanket from Example 8 and air duct board from Example 9 was determined in accordance with internal test method K-157, “Ignition Loss of Cured Blanket (LOI).” The test was performed on a sample in a wire tray placed in a furnace at 1000° F., +/−50° F., for 15 to 20 minutes to ensure complete oxidation, after which treatment the resulting sample was weighed.

Parting Strength

The parting strength of cured blanket from Example 8, R30 residential blanket from Example 10, and R19 residential blanket from Example 11 were determined in accordance with internal test method KRD-161, which test method is virtually identical to ASTM C 686, “Parting Strength of Mineral Fiber Batt and Blanket-Type Insulation.”

Durability of Parting Strength

The durability of parting strength for R30 residential blanket from Example 10 and R19 residential blanket from Example 11 were determined in accordance with ASTM C 686, “Parting Strength of Mineral Fiber Batt and Blanket-Type Insulation,” following one-week conditioning at 90° F. and 95% relative humidity.

Tensile Strength

The tensile strength of cured blanket from Example 8 and R19 residential blanket from Example 11 was determined in accordance with an internal test method KRD-161, “Tensile Strength Test Procedure.” The test was performed on samples die cut in both the machine direction and the cross-cut machine direction. Samples were conditioned for 24 hours at 75° F. and 50% relative humidity. Ten samples in each machine direction were tested in a test environment of 75° F., 50% relative humidity. The dogbone specimen was as specified in ASTM D638, “Standard Test Method for Tensile Properties of Plastics.” A cross-head speed of 2 inches/minute was used for all tests.

Bond Strength

The inter-laminar bond strength of cured blanket from Example 8, R30 residential blanket from Example 10, and R19 residential blanket from Example 11 was determined using an internal test method KRD-159, “Bond Strength of Fiberglass Board and Blanket Products.” Molded specimens with a cross sectional area of 6 inches by 6 inches were glued to 6 inch by 7 inch specimen mounting plates and placed in a fixture that applied the force perpendicular to the surface of the specimen. A cross-head speed of 12 inches per minute was used for all tests.

Thickness Recovery

Out-of-package and rollover thickness tests were performed on cured blanket from Example 8 using internal test methods K-123, “Recovered Thickness—End of Line Dead Pin Method—Roll Products,” and K-109, “Test Procedure for Recovered Thickness of Roll Products—Rollover Method.” Recovered thickness was measured by forcing a pin gauge through a sample of cured blanket from a roll product, either 15 minutes after packaging or at a later point in time, until the pin contacts a flat, hard surface underlying the sample, and then measuring the recovered thickness with a steel rule. Thickness tests were performed on R30 residential blanket from Example 10 and R19 residential blanket from Example 11 using internal test methods K-120, “Test Procedure for Determining End-of-Line Dead-Pin Thickness—Batts,” and K-128, “Test Procedure for Recovered Thickness of Batt Products—Drop Method,” both of which test methods are similar to ASTM C 167, “Standard Test Methods for Thickness and Density of Blanket or Batt Thermal Insulations.”

Dust Testing

Dust testing was performed on cured blanket from Example 8, R30 residential blanket from Example 10, and R19 residential blanket from Example 11 using internal test procedure K-102, “Packaged Fiber Glass Dust Test, Batt Method.” Dust liberated from randomly selected samples (batts) of cured blanket, R30 residential blanket, and R19 residential blanket dropped into a dust collection box was collected on a filter and the amount of dust determined by difference weighing.

Water Absorption

Water absorption (% by weight) tests were performed on cured blanket from Example 8 and R19 residential blanket from Example 11 using ASTM C 1104, “Test Method for Determining the Water Vapor Absorption of Unfaced Mineral Fiber Insulation.”

Flexural Rigidity (EI)

The flexural rigidity of air duct board from Example 9, which is the force couple required to bend the rigid air duct board, i.e., the product of E, the modulus of elasticity, and I, the bending moment of inertia, was determined in accordance with NAIMA AHS 100-74, “Test Method for Flexural Rigidity of Rectangular Rigid Duct Materials.”

Stiffness-Rigidity

Stiffness-rigidity testing was performed on R19 residential blanket from Example 11 using internal test procedure K-117, “Test Procedure for Rigidity of Building Insulation.” A sample of R19 residential blanket, approximately 47.5 inches in length (±0.5 inch), was placed on the center support bar of a stiffness test apparatus, which apparatus included a protractor scale directly behind the center support bar. With the ends of the sample hanging free, the angle (in degrees) at each end of the sample was recorded by sighting along the bottom edge of the sample while reading the protractor scale.

Compressive Resistance

The compressive resistance of air duct board from Example 9 was determined in accordance with ASTM C 165, “Standard Test Method for Measuring Compressive Properties of Thermal Insulations.”

Conditioned Compressive Resistance

The conditioned compressive resistance of air duct board from Example 9, after one week at 90° F. and 95% relative humidity, was determined in accordance with ASTM C 165, “Standard Test Method for Measuring Compressive Properties of Thermal Insulations.”

Compressive Modulus

The compressive modulus of air duct board from Example 9 was determined in accordance with ASTM C 165, “Standard Test Method for Measuring Compressive Properties of Thermal Insulations.”

Conditioned Compressive Modulus

The conditioned compressive modulus of air duct board from Example 9, after one week at 90° F. and 95% relative humidity, was determined in accordance with ASTM C 165, “Standard Test Method for Measuring Compressive Properties of Thermal Insulations.”

Hot Surface Performance

Hot surface performance tests were performed on cured blanket from Example 8, R30 residential blanket from Example 10, and R19 residential blanket from Example 11 using ASTM C 411, “Test Method for Hot Surface Performance of High Temperature Thermal Insulation.” Hot surface performance tests were conducted on 3×6-inch sections of cured pipe insulation product from Example 12 at 650° F. and 1000° F. using ASTM C 411, “Test Method for Hot Surface Performance of High Temperature Thermal Insulation.” There was no measurable internal temperature rise in the insulation above the pipe hot surface temperature.

Corrosivity on Steel

Corrosivity testing was performed on R30 residential blanket from Example 10 and R19 residential blanket from Example 11 versus steel coupons using internal test procedure Knauf PTL-14, which is virtually identical to ASTM C 665.

Smoke Development on Ignition

Smoke development on ignition for cured blanket from Example 8, with calculation of specific extinction area (SEA), was determined by cone calorimetry using ASTM E 1354, “Test Method for Heat and Visible Smoke Release Rates for Materials and Products Using an Oxygen Consumption calorimeter.”

Gaseous Compounds Produced During Pyrolysis

Gaseous compounds producing during pyrolysis of cured blanket from Example 8 were determined as follows: Approximately 10 g of cured blanket was placed in a test tube, which tube was then heated to 1000° F. for 2.5 minutes at which time the headspace was sampled and analyzed by gas chromatography/mass spectrometry (GC/MS) under the following conditions: Oven, 50° C. for one minute ˜10° C./minute to 300° C. for 10 minutes; Inlet, 280° C. splitless; Column, HP-5 30 mm×0.32 mm×0.25 um; Column flow, 1.11 mL/minute Helium; Detector, MSD 280° C.; Injection volume, 1 mL; Detector mode, scan 34-700 amu; Threshold, 50; and Sampling Rate, 22 scans/second. A computer search of the mass spectrum of a chromatographic peak in the sample was made against the Wiley library of mass spectra. The best match was reported. A quality index (closeness of match to the library spectra) ranging from 0 to 99 was generated. Only the identity of peaks with a quality index of greater than or equal to 90 were reported.

Gaseous Compounds Produced During Thermal Curing

Gaseous compounds producing during thermal curing of pipe insulation uncured from Example 12 were determined as follows: Approximately 0.6 g of pipe insulation uncured was placed in a test tube, which tube was then heated to 540° F. for 2.5 minutes at which time the headspace was sampled and analyzed by gas chromatography/mass spectrometry under the following conditions: Oven, 50° C. for one minute ˜10° C./minute to 300° C. for 10 minutes; Inlet, 280° C. splitless; Column, HP-5 30 mm×0.32 mm×0.25 um; Column flow, 1.11 mL/minute Helium; Detector, MSD 280° C.; Injection volume, 1 mL; Detector mode, scan 34-700 amu; Threshold, 50; and Sampling Rate, 22 scans/second. A computer search of the mass spectrum of a chromatographic peak in the sample was made against the Wiley library of mass spectra. The best match was reported. A quality index (closeness of match to the library spectra) ranging from 0 to 99 was generated. Only the identity of peaks with a quality index of greater than or equal to 90 were reported.

Example 16 Preparation of Triammonium Citrate-Dextrose (1:6) Binder/Cellulose Fiber Composition: Wood Fiber Board

Several methods were used to produce wood fiber boards/sheets bonded with triammonium citrate-dextrose (1:6) binder. A representative method, which method produced strong, uniform samples, is as follows: Wood in the form of assorted pine wood shavings and sawdust was purchased from a local farm supply store. Wood fiber board samples were made with the “as received” wood and also material segregated into the shavings and sawdust components. Wood was first dried in an oven at approximately 200° F. over night, which drying resulted in moisture removal of 14-15% for the wood shavings and about 11% for the sawdust. Thereafter, dried wood was placed in an 8 inch high×12 inch wide×10.5 inch deep plastic container (approximate dimensions). Triammonium citrate-dextrose (1:6) binder was prepared (36% in binder solids) as described in Example 5, and then 160 g of binder was sprayed via an hydraulic nozzle onto a 400-g sample of wood in the plastic container while the container was inclined 30-40 degrees from the vertical and rotated slowly (approximately 5-15 rpm). During this treatment, the wood was gently tumbled while becoming uniformly coated.

Samples of resinated wood were placed in a collapsible frame and compressed in between heated platens under the following conditions: resinated wood shavings, 300 psi; resinated sawdust, 600 psi. For each resinated sample, the cure conditions were 350° F. for 25 to 30 minutes. The resulting sample boards were approximately 10 inches long×10 inches wide, and about 0.4 inches thick before trimming, well-bonded internally, smooth surfaced and made a clean cut when trimmed on the band saw. Trimmed sample density and the size of each trimmed sample board produced were as follows: sample board from wood shavings, density ˜54 pcf, size 8.3 inches long×9 inches wide×0.36 inches thick; sample board from sawdust, density 44 pcf, size ˜8.7 inches long×8.8 inches wide×0.41 inches thick. The estimated binder content of each sample board was ˜12.6%.

TABLE 1 Testing/Evaluation Results for Cured Triammonium citrate-Dextrose Binder Samples^(a) BINDER COMPOSITION Wet Water Wet Water Wet Water Triammonium citrate ^(b):Dextrose•H₂O ^(c) Strength Color Strength Color Strength Color Mass Ratio Mole Ratio^(d) COOH:OH Ratio^(d) (400° F.) (400° F.) (350° F.) (350° F.) (300° F.) (300° F.)  1:24 (1:30) 0.02:1 Dissolved Light Dissolved Light Dissolved Light caramel- caramel- caramel- colored colored colored  1:12 (1:15) 0.04:1 Impervious Clear and Dissolved Caramel- Dissolved Caramel- colorless colored colored 1:8 (1:10) 0.06:1 Impervious Clear and Partially Caramel- Dissolved Caramel- colorless Dissolved colored colored 1:6 (1:7)  0.08:1 Impervious Clear and Softened Clear Dissolved Caramel- colorless yellow colored 1:5 (1:6)  0.10:1 Impervious Clear and Softened Clear Dissolved Caramel- colorless yellow colored  1:4^(e) (1:5)^(e )  0.12:1^(e) Impervious Clear and Softened Clear Dissolved Caramel- colorless yellow colored  1:3^(e) (1:4)^(e )  0.15:1^(e) Impervious Clear and Softened Clear Dissolved Caramel- colorless orange colored ^(a)From Example 1 ^(b)MW = 243 g/mol; 25% (weight percent) solution ^(c)MW = 198 g/mol; 25% (weight percent) solution ^(d)Approximate ^(e)Associated with distinct ammonia smell

TABLE 2 Elemental Analysis Results for Cured Triammonium Citrate-Dextrose (1:6) Binder Samples^(a) as a Function of Temperature and Time Elemental Elemental Analysis Results Cure Temp Cure Time Analysis C:H C:N 300° F. 1 hour Carbon 48.75% 8.70 11.89 Hydrogen 5.60% Nitrogen 4.10% 300° F. 1 hour Carbon 49.47% 8.91 12.00 Hydrogen 5.55% Nitrogen 4.12% 300° F. 1 hour Carbon 50.35% 9.31 12.04 Hydrogen 5.41% Avg: -- 8.97 11.98 Nitrogen 4.18% 350° F. 0.5 hour Carbon 52.55% 10.10 12.36 Hydrogen 5.20% Nitrogen 4.25% 350° F. 0.5 hour Carbon 54.19% 10.67 12.31 Hydrogen 5.08% Nitrogen 4.40% 350° F. 0.5 hour Carbon 52.86% 10.22 12.47 Hydrogen 5.17% Avg. -- 10.33 12.38 Nitrogen 4.24% 400° F. 0.33 hour Carbon 54.35% 10.68 12.21 Hydrogen 5.09% Nitrogen 4.45% 400° F. 0.33 hour Carbon 55.63% 10.99 12.15 Hydrogen 5.06% Nitrogen 4.58% 400° F. 0.33 hour Carbon 56.10% 11.47 12.06 Hydrogen 4.89% Avg. -- 11.05 12.14 Nitrogen 4.65% ^(a)From Example 4

TABLE 3 Measured Tensile Strength for Glass Bead Shell Bone Compositions^(a) Prepared With Triammonium Citrate-Dextrose (1:6) Binder^(b) vs. Standard PF Binder Mean^(c) Mean^(c) Weathered:Dry Dry Weathered Tensile Tensile Tensile Strength Strength Strength Binder Description Ratio (psi) (psi) Triammonium Citrate-Dextrose^(d) 0.71 286 202 Triammonium Citrate-Dextrose^(d) 0.76 368 281 Triammonium Citrate-Dextrose^(d) 0.79 345 271 Triammonium Citrate-Dextrose^(d) 0.77 333 256 Triammonium Citrate-Dextrose^(d) 0.82 345 284 Triammonium Citrate-Dextrose^(d) 0.75 379 286 Triammonium Citrate-Dextrose^(d) 0.74 447 330 Triammonium Citrate-Dextrose^(e)  0.76^(e)  358^(e)  273^(e) Triammonium Citrate-Dextrose: Day Binder Made 0.79 345 271 1 Day After Binder Made 0.76 352 266 2 Day After Binder Made 0.72 379 272 1 Week After Binder Made 0.88 361 316 2 Weeks After Binder Made 0.82 342 280 Triammonium citrate-Dextrose with Silane Substitution: SILQUEST A-187 silane 0.69 324 222 substituted 1:1 by weight for SILQUEST A-1101 SILQUEST A-187 silane 0.71 351 250 substituted 2:1 by weight for SILQUEST A-1101 HYDROSIL 2627 silane 0.87 337 293 substituted 1:1 by weight for SILQUEST A-1101 HYDROSIL 2627 silane 0.99 316 312 substituted 2:1 by weight for SILQUEST A-1101 Z-6020 silane 0.78 357 279 substituted 1:1 by weight for SILQUEST A-1101 Z-6020 silane 0.78 373 291 substituted 2:1 by weight for SILQUEST A-1101 Standard PF (Ductliner) Binder 0.79 637 505 ^(a)From Example 6 ^(b)From Example 5 ^(c)Mean of nine shell bone samples ^(d)One of seven different batches of triammonium citrate-dextrose (1:6) binder made over a five-month period ^(e)Average of seven different batches of triammonium citrate-dextrose (1:6) binder made over a five-month period

TABLE 4 Measured Tensile Strength for Glass Bead Shell Bone Compositions^(a) Prepared With Triammonium Citrate-Dextrose (1:6) Binder Variants^(b) vs. Standard PF Binder Quantity of Mean^(c) Mean^(c) Additive in Weathered:Dry Dry Weathered 300 g of Tensile Tensile Tensile binder Strength Strength Strength Binder Description (grams) Ratio (psi) (psi) Triammonium —  0.76^(d)  358^(d)  273^(d) citrate- Dextrose^(d) Triammonium citrate- Dextrose with Additive: SilresBS 1042^(e) 1.6 0.84 381 325 SilresBS 1042 3.2 0.94 388 363 SilresBS 1042 4.8 1.01 358 362 Sodium Carbonate 0.45 0.88 281 248 Sodium Carbonate 0.9 0.71 339 242 Sodium Carbonate 1.35 0.89 282 251 Silres BS 1042 + 1.6 + 1.35 0.84 335 280 Sodium Carbonate Silres BS 1042 + 3.2 + 0.9  0.93 299 277 Sodium Carbonate Silres BS 1042 + 4.8 + 0.48 0.73 368 270 Sodium Carbonate Sodium Carbonate^(f) 0.9 0.83 211 175 Sodium Carbonate^(f) 0.9 0.69 387 266 Sodium Carbonate 1.8 0.81 222 180 Sodium Carbonate⁸ 1.8 0.66 394 259 LE 46^(h) 6.4 0.80 309 248 LE 46 12.9 0.98 261 256 TPX5688/AQUA- 5.6 0.78 320 250 TRETE BSM40^(i) Silres BS 1042 6.4 0.91 308 280 Trimethylmethoxy- 0.9 0.78 262 205 silane Potassium Perman- 0.2 0.69 302 207 ganate PGN^(j) 9 0.82 246 201 Cloisite NA+^(k) 9 0.71 280 199 Blown Soya 18 1.04 239 248 Emulsion (25%)^(l) Flaxseed Oil 18 0.90 362 326 Emulsion (25%) Bentolite L-10^(m) 9 1.00 288 288 Michem 45745 PE 9 0.81 335 270 Emulsion (50%)^(n) Bone Glue Solution^(o) 15 0.82 435 358 Tannic Acid 4.5 0.79 474 375 Glycine 4.5 0.80 346 277 Glycerol 5.28 0.69 361 249 Sodium Tetraborate 0.9 + 4.5  0.74 378 280 Decahydrate + Glycerol 0.9 0.86 387 331 Sodium Tetraborate Decahydrate 1% Sodium Tetraborate 1.8 0.80 335 267 Decahydrate 2% Sodium Tetraborate 2.5 0.84 334 282 Decahydrate 3% Axel INT-26-LF95^(p) 0.9 0.70 374 263 ISO Chill Whey^(q) 0.9 0.74 444 328 1% ISO Chill Whey 2% 1.8 1.01 407 412 ISO Chill Whey 5% 4.5 NC^(r) 473 NM^(s) Resorcinol 5% 4.5 0.76 331 251 Maltitol 3.23 0.82 311 256 1,5-Pentanediol 4.5 0.74 451 333 1,5-Pentanediol 9 0.67 488 327 1,5-Pentanediol 13.5 0.85 459 389 1,6-Hexanediol 4.5 0.84 462 387 1,6-Hexanediol 9 0.67 529 353 1,6-Hexanediol 13.5 0.78 547 427 polyTHF₂₅₀ ^(t) 4.5 0.75 475 357 polyTHF₂₅₀ 9 0.69 485 337 polyTHF₂₅₀ 13.5 0.69 463 321 Textrion whey 0.9 1.13 420 475 Textrion whey 1.8 0.96 469 445 polyTHF₆₅₀ ^(u) 4.5 0.95 399 379 polyTHF₆₅₀ 9 0.94 397 372 polyTHF₆₅₀ 13.5 0.95 371 353 Glycerol 4.5 0.75 326 245 Glycerol 9 0.63 370 233 Glycerol 13.5 0.59 372 220 Glycerol 18 0.65 339 221 Sorbitol 4.5 0.85 352 300 Sorbitol 9 0.75 402 301 Sorbitol 13.5 0.73 374 272 TMP^(v) 4.5 0.78 496 386 TMP 9 0.85 466 395 TMP 13.5 0.84 489 412 PETol^(w) 4.5 0.81 431 349 PETol 9 0.90 370 334 PETol 13.5 0.64 445 286 Standard PF — 0.79 637 505 (Ductliner) Binder ^(a)From Example 6 ^(b)From Example 5 ^(c)Mean of nine shell bone samples ^(d)Average of seven different batches of triammonium citrate-dextrose (1:6) binder made over a five-month period ^(e)Silres BS 1042 to be 50% solids emulsion of methylhydrogen polysiloxane ^(f)Replicate samples ^(g)Replicate sample ^(h)LE 46 to be 35% solids emulsion of polydimethylsiloxane ^(i)TPX5688/AQUA-TRETE BSM40 to be 40% emulsion of alkylsilane ^(j)PGN, a grade of clay, montmorillonite, from Nanocor ^(k)Cloisite NA+, the sodium salt of a clay from Southern Clay Products ^(l)Blown Soya Emulsion (25%), a 25% solids emulsion of soybean oil with PEG 400 dioleate (4% on solids) and guar gum (1% on solids) ^(m)Bentolite L-10, a clay from Southern Clay Products ^(n)Michem 45745 PE Emulsion (50%), a 25% solids emulsion of low molecular weight polyethylene ^(o)Bone Glue Solution, a 30% solids solution ^(p)Axel INT-26-LF95, a fat-based, mold-release agent/emulsion ^(q)ISO Chill Whey 9010 ^(r)Not calculated ^(s)Not measured ^(t)polyTetrahydrofuran (OH—(CH₂—CH₂—CH₂—CH₂—O—)_(n)—H) with molecular weight = 250 ^(u)polyTetrahydrofuran (OH—(CH₂—CH₂—CH₂—CH₂—O—)_(n)—H) with molecular weight = 650 ^(v)Trimethylol propane ^(w)Pentaerythritol

TABLE 5 Measured Tensile Strength for Glass Bead Shell Bone Compositions^(a) Prepared With Ammonium Polycarboxylate-Dextrose Binder Variants^(b) vs. Polycarboxylic Acid-based Binders vs. Standard PF Binder Mean^(c) Mean^(c) Weathered:Dry Dry Weathered Tensile Tensile Tensile Strength Strength Strength Binder Description Ratio (psi) (psi) Triammonium citrate-dextrose  0.76^(d)  358^(d)  273^(d) (1:6)^(d) Triammonium citrate-dextrose 0.68 377 257 (1:5) +Sodium carbonate (0.9 g) 0.71 341 243 +Sodium carbonate (1.8 g) 0.78 313 243 AQUASET-529 + Dex + 0.41 499 205 Ammonia^(e) AQUASET-529 + Dex + Silane^(f) 0.57 541 306 AQUASET-529 + Ammonia + 0.11 314  33 Silane^(g) AQUASET-529 + Silane^(h) 0.48 605 293 PETol + Maleic Acid + Silane^(i) 0.73 654 477 PETol + Maleic Acid + TSA + 0.64 614 390 Silane^(j) [Binder^(j) + Ammonia + Dex + 0.58 420 245 Silane]^(k) PETol + Citric Acid + Silane^(l) 0.56 539 303 CRITERION 2000 + Glycerol^(m) 0.26 532 136 CRITERION 2000 + Glycerol^(n) 0.20 472  95 SOKALAN + Dex + Ammonia^(o) 0.66 664 437 NF1 + Dex + Ammonia^(p) 0.50 877 443 Standard PF (Ductliner) Binder 0.79 637 505 ^(a)From Example 6 ^(b)From Example 5 ^(c)Mean of nine shell bone samples ^(d)Average of seven different batches of triammonium citrate-dextrose (1:6) binder made over a five-month period ^(e)200 g AQUASET-529 + 87 g 19% ammonia + 301 g Dextrose + 301 g water to be a 30% solution ^(f)300 mL of solution from binder^(e) + 0.32 g of SILQUEST A-1101 ^(g)200 g AQUASET-529 + 87 g 19% ammonia + 101 g water + 0.6 g SILQUEST A-1101 ^(h)AQUASET-529 + SILQUEST A-1101 (at 0.5% binder solids), diluted to 30% solids ^(i)136 g pentaerythritol + 98 g maleic anhydride + 130 g water, refluxed for 30 minutes; 232 g of resulting solution mixed with 170 g water and 0.6 g of SILQUEST A-1101 ^(j)136 g pentaerythritol + 98 g maleic anhydride + 130 g water + 1.5 mL of 66% p-toluenesulfonic acid, refluxed for 30 minutes; 232 g of resulting solution mixed with 170 g water and 0.6 g of SILQUEST A-1101 ^(k)220 g of binder^(i) + 39 g of 19% ammonia +135 g Dextrose + 97 g water + 0.65 g SILQUEST A-1101 ^(l)128 g of citric acid + 45 g of pentaerythritol + 125 g of water, refluxed for 20 minutes; resulting mixture diluted to 30% solids and SILQUEST A-1101 added at 0.5% on solids ^(m)200 g of Kemira CRITERION 2000 + 23 g glycerol + 123 g water + 0.5 g SILQUEST A-1101 ^(n)200 g of Kemira CRITERION 2000 + 30 g glycerol + 164 g water + 0.6 g SILQUEST A-1101 ^(o)100 g of BASF SOKALAN CP 10 S + 57 g 19% ammonia + 198 g Dextrose + 180 g water + 0.8 g SILQUEST A-1101 ^(p)211 g of H. B. Fuller NF1 + 93 g 19% ammonia + 321 g Dextrose + 222 g water + 1.33 g SILQUEST A-1101

TABLE 6 Measured Tensile Strength for Glass Bead Shell Bone Compositions^(a) Prepared With Ammonium Polycarboxylate-Sugar Binder Variants^(b) vs. Standard PF Binder Mean^(c) Mean^(c) Weathered:Dry Dry Weathered Tensile Tensile Tensile Strength Strength Strength Binder Description Molar Ratio Ratio (psi) (psi) Triammonium citrate-Dextrose^(d) Dextrose = 2xCOOH  0.76^(d)  358^(d)  273^(d) Triammonium citrate-DHA^(e) DHA = 2xCOOH 1.02 130 132 Triammonium citrate-Xylose Xylose = 2xCOOH 0.75 322 241 Triammonium citrate-Fructose Fructose = 2xCOOH 0.79 363 286 Diammonium tartarate-Dextrose Dextrose = 2xCOOH 0.76 314 239 Diammonium maleate-Dextrose Dextrose = 2xCOOH 0.78 393 308 Diammonium maliate-Dextrose Dextrose = 2xCOOH 0.67  49 280 Diammonium succinate-Dextrose Dextrose = 2xCOOH 0.70 400 281 Ammonium lactate^(f)-Dextrose Dextrose = 2xCOOH 0.68 257 175 Ammonia + tannic acid^(g)-Dextrose Dextrose = 2 x NH₄ ^(+h) 0.50 395 199 Standard PF (Ductliner) Binder — 0.79 637 505 ^(a)From Example 6 ^(b)From Example 5 ^(c)Mean of nine shell bone samples ^(d)Average of seven batches ^(e)DHA = dihydroxyacetone ^(f)Monocarboxylate ^(g)Non-carboxylic acid ^(h)pH ≥ 7

TABLE 7 Measured Tensile Strength and Loss on Ignition for Glass Fiber Mats^(a) Prepared With Ammonium Polycarboxylate-Sugar (1:6) Binder Variants^(b) vs. Standard PF Binder Mean^(c) Mean^(c) Weathered:Dry Dry Weathered Mean Tensile Tensile Tensile % Strength Strength Strength Binder Composition LOI Ratio (lb force) (lb force) Triammonium citrate- 5.90 0.63 11.4 7.2 Dex^(d) Triammonium citrate- 6.69 0.72 14.6 10.5 Dex Diammonium maliate- 5.02 0.86 10.2 8.8 Dex Diammonium maliate- 6.36 0.78 10.6 8.3 Dex Diammonium succinate- 5.12 0.61 8.0 4.9 Dex Diammonium succinate- 4.97 0.76 7.5 5.7 Dex Triammonium citrate- 5.80 0.57 11.9 6.8 Fruc^(e) Triammonium citrate- 5.96 0.60 11.4 6.8 Fruc Diammonium maliate- 6.01 0.60 9.0 5.4 Fruc Diammonium maliate- 5.74 0.71 7.9 5.6 Fruc Diammonium succinate- 4.60 1.05 3.7 3.9 Fruc Diammonium succinate- 4.13 0.79 4.4 3.5 Fruc Triammonium citrate- 4.45 0.96 4.7 4.5 DHA^(f) Triammonium citrate- 4.28 0.74 5.4 4.0 DHA Triammonium citrate- 3.75 0.52 8.5 4.4 DHA-Glycerol^(g) Triammonium citrate- 3.38 0.59 8.0 4.7 DHA-Glycerol^(g) Triammonium citrate- 4.96 0.61 10.7 6.5 DHA-PETol^(h) Triammonium citrate- 5.23 0.65 9.4 6.1 DHA-PETol^(h) Triammonium citrate- 5.11 0.74 15.7 11.6 DHA-PVOH^(i) Triammonium citrate- 5.23 0.85 14.9 12.6 DHA-PVOH^(i) Standard PF Binder^(j) 7.22 0.75 15.9 12.0 Standard PF Binder^(j) 8.05 0.75 18.8 14.2 ^(a)From Example 7 ^(b)From Example 5 ^(c)Mean of three glass fiber mats ^(d)Dex = Dextrose ^(e)Fruc = Fructose ^(f)DHA = Dihydroxyacetone ^(g)Glycerol substituted for 25% of DHA by weight ^(h)PETol = Pentaerythritol substituted for 25% of DHA by weight ^(i)PVOH = Polyvinyl alcohol (86-89% hydrolyzed polyvinyl acetate, MW ~22K-26K), substituted for 20% of DHA by weight ^(j)Ductliner binder

TABLE 8 Testing Results for Cured Blanket from Example 8: Triammonium citrate-Dextrose (1:6) Binder vs. Standard PF Binder Melanoidin- PF Binder - Fiberglass Fiberglass BINDER Cured Blanket Cured Blanket % of TEST “BINDER” “STANDARD” STANDARD Density 0.65 0.67 97% Loss on Ignition (%) 13.24% 10.32% 128%  Thickness Recovery 1.46 1.59 92% (dead, in.) Thickness Recovery 1.55 1.64 94% (drop, in.) Dust (mg) 8.93 8.80 102%  Tensile Strength (lb/in. width) Machine Direction 2.77 3.81 73% Cross Machine Dir. 1.93 2.33 83% Avg. 2.35 3.07 76% Parting Strength (g/g) Machine Direction 439.22 511.92 86% Cross Machine 315.95 468.99 67% Direction Avg. 377.59 490.46 77% Bond Strength (lb/ft²) 11.58 14.23 81% Water Absorption 1.24% 1.06% 116%  (% by weight) Hot Surface Pass Pass — Performance Product Emissions (at 96 Hours) Total VOCs (μg/m³) 0 6  0% Total HCHO (ppm) 0 56  0% Total Aldehydes (ppm) 6 56 11%

TABLE 9 Smoke Development on Ignition for Cured Blanket from Example 8: Triammonium citrate-Dextrose (1:6) Binder vs. Standard PF Binder Average SEA^(a) External Melanoidin-Fiberglass PF Binder-Fiberglass Heat Flux Cured Blanket Cured Blanket 35 kW/m² 2,396 m²/kg 4,923 m²/kg 35 kW/m² 1,496 m²/kg 11,488 m²/kg  35 kW/m² 3,738 m²/kg 6,848 m²/kg Overall Avg. = 2,543 m²/kg Overall Avg. = 7,756 m²/kg 50 kW/m² 2,079 m²/kg 7,305 m²/kg 50 kW/m² 3,336 m²/kg 6,476 m²/kg 50 kW/m² 1,467 m²/kg 1,156 m²/kg Overall Avg. = 2,294 m²/kg Overall Avg. = 4,979 m²/kg ^(a)SEA = specific extinction area

TABLE 10 Testing Results for Air Duct Board from Example 9: Triammonium citrate-Dextrose (1:6) Binder vs. Standard PF Binder Melanoidin- PF Binder - Fiberglass Fiberglass BINDER Air Duct Board Air Duct Board % of TEST “BINDER” “STANDARD” STANDARD Density 4.72 4.66 101% Loss on Ignition (%) 18.5% 16.8% 110% Flexural Rigidity (lb in²/in width) Machine Direction 724 837  86% Cross Machine Dir. 550 544 101% Avg. 637 691  92% Compressive (psi) 0.67 0.73  92% Resistance at 10% Compressive (psi) 1.34 1.34 100% Resistance at 20% Conditioned 0.719 0.661 109% Compressive (psi) Resistance at 10% Conditioned 1.31 1.24 106% Compressive (psi) Resistance at 20% Compressive 6.85 7.02  97% Modulus (psi) Conditioned 6.57 6.44 102% Compressive Modulus (psi) Product Emissions (at 96 Hours) Total VOCs (μg/m³) 40 39 102% Total HCHO (ppm) 0.007 0.043  16% Total Aldehydes (ppm) 0.007 0.043  16%

TABLE 11 Testing Results for R30 Residential Blanket from Example 10: Triammonium citrate-Dextrose (1:6) Binder vs. Standard PF Binder PF Binder ^(a) Binder^(b) Binder^(c) Binder Test (% of Std) (% of Std) (% of Std) Std Thickness recovery (dead, in.): 1 week 10.05 (97%) 10.36 (99%) 9.75 (94%) 10.38 6 week 7.17 (91%) 7.45 (94%) 7.28 (92%) 7.90 Thickness recovery (drop, in.): 1 week 11.06 (101%) 4.23 (102%) 11.01 (100%) 11.00 6 week 9.07 (101%) 9.06 (101%) 9.31 (103%) 8.99 Parting Strength (g/g) Machine Direction 214.62 (78%) 186.80 (68%) 228.22 (83%) 275.65 Cross Machine 219.23 (75%) 202.80 (70%) 210.62 (72%) 290.12 Direction Average 216.93 (77%) 194.80 (69%) 219.42 (77%) 282.89 Durability of Parting Strength (g/g) Machine Direction 214.62 (84%) 209.54 (82%) 259.58 (102%) 254.11 Cross Machine 219.23 (87%) 204.12 (81%) 221.44 (88%) 252.14 Direction Average 216.93 (86%) 206.83 (82%) 240.51 95%) 253.13 Bond Strength (lb/ft2) 1.86 (84%) NM^(d) NM^(d) 2.20 Dust (mg) 0.0113 (79%) 0.0137 (96%) 0.0101 (71%) 0.0142 Hot Surface Performance Pass Pass Pass Pass (pass/fail) Corrosivity (steel) Pass Pass Pass NM^(d) (pass/fail) ^(a) Melanoidin binder; nominal machine condition to produce loss on ignition of 5% ^(b)Melanoidin binder; machine adjustment to increase loss on ignition to 6.3% ^(c)Melanoidin binder; machine adjustment to increase loss on ignition to 6.6% ^(d)Not measured

TABLE 12 Testing Results for R19 Residential Blanket from Example 11 (Batch A-1): Triammonium citrate- Dextrose (1:6) Binder vs. Standard PF Binder Melanoidin- PF Binder - Fiberglass Fiberglass R19 R19 BINDER Residential Residential % of TEST “BINDER” “STANDARD” STANDARD Thickness Recovery (dead, in.): 1 week 6.02 6.05 99% 5 week 6.15 6.67 92% 6 week 4.97 5.14 97% 3 month 6.63 6.20 107%  Thickness Recovery (drop, in.): 1 week 6.79 6.69 101%  4 week 6.92 7.11 97% 6 week 5.83 6.07 96% 3 month 7.27 6.79 107%  Dust (mg) 2.88 8.03 36% Tensile Strength (lb/in. width) Machine Direction 2.42 3.47 70% Cross Machine Dir. 2.00 3.03 66% Average 2.21 3.25 68% Parting Strength (g/g) Machine Direction 128.18 173.98 74% Cross Machine 118.75 159.42 74% Direction Average 123.47 166.70 74% Durability of Parting Strength (g/g) Machine Direction 143.69 161.73 89% Cross Machine 127.30 149.20 85% Direction Average 135.50 155.47 87% Bond Strength 1.97 2.37 83% (lb/ft²) Water Absorption 7.1 7.21 98% (%) Hot Surface Pass Pass — Performance Corrosion Pass Pass — Stiffness-Rigidity 49.31 44.94 110% 

TABLE 13 Testing Results for R19 Residential Blanket from Example 11: Triammonium citrate-Dextrose (1:6) Binder Variants vs. Standard PF Binder Binder Batch Binder Batch Binder Batch Binder Batch A-2^(a) B^(a) C^(a) D^(a) Test (% of Std) (% of Std) (% of Std) (% of Std) PF Binder Std. Thickness recovery (dead, in.): 1 week 5.94 (99%) 5.86 (98%) 6.09 (101%) 6.25 (104%) 6.01 6 week 4.86 (91%) 5.29 (99%) 5.0 (93%) 5.10 (95%) Thickness recovery (drop, in.): 1 week 6.83 (105%) 6.7025 (103%) 6.81 (104%) 6.88 (105%) 6.00 6 week 5.76 (96%) 6.02 (100%) 5.89 (98%) 6.00 (100%) Tensile Strength (lb/in) Machine Direction 1.28 (36%) 1.40 (39%) 1.71 (48%) 1.55 (43%) 3.58 Cross Machine Direction 1.65 (71%) 1.21 (52%) 1.12 (48%) 1.12 (48%) 2.31 Average 1.47 (50%) 1.31 (44%) 1.42 (48%) 1.34 (45%) 2.95 Parting Strength (g/g) Machine Direction 111.82 (42%) 164.73 (62%) 136.00 (51%) 164.56 (62%) 264.81 Cross Machine Direction 140.11 (85%) 127.93 (78%) 126.46 (77%) 108.44 (66%) 164.60 Average 125.97 (59%) 146.33 (68%) 131.23 (61%) 136.50 (64%) 214.71 Durability of Parting Strength (g/g) Machine Direction 138.55 (72%) 745.62 (76%) 113.37 (59%) 176.63 (92%) 191.20 Cross Machine Direction 158.17 (104%) 116.44 (77%) 97.10 (64%) 162.81 (107%) 151.49 Average 148.36 (86%) 131.03 (76%) 105.24 (61%) 169.72 (99%) 171.35 Bond Strength (lb/ft2) 1.30 (52%) 1.50 (60%) 1.60 (64%) 1.60 (64%) 2.50 Dust (mg) 0.0038 (86%) 0.0079 (179%) 0.0053 (120%) 0.0056 (126%) 0.0044 Stiffness-Rigidity (degrees) 57.50 (N/A) 55.50 (N/A) 61.44 (N/A) 59.06 (N/A) 39.38 ^(a)Melanoidin binder

TABLE 14 GC/MS Analysis of Gaseous Compounds Produced During Pyrolysis of Cured Blanket (from Example 8) Prepared With Ammonium Citrate-Dextrose (1:6) Binder Retention Time (min) Tentative Identification % Peak Area 1.15 2-cyclopenten-1-one 10.67 1.34 2,5-dimethyl-furan 5.84 3.54 furan 2.15 3.60 3-methyl-2,5-furandione 3.93 4.07 phenol 0.38 4.89 2,3-dimethyl-2-cyclopenten-1-one 1.24 5.11 2-methyl phenol 1.19 5.42 4-methyl phenol 2.17 6.46 2,4-dimethyl-phenol 1.13 10.57 dimethylphthalate 0.97 17.89 octadecanoic acid 1.00 22.75 erucylamide 9.72

TABLE 15 GC/MS Analysis of Gaseous Compounds Produced During Thermal Curing of Pipe Insulation Uncured (from Example 12) Prepared With Ammonium Citrate-Dextrose (1:6) Binder Retention Time (min) Identification % Peak Area 1.33 2,5-dimethylfuran 1.02 2.25 furfural OR 3-furaldehyde 2.61 2.48 2-furanmethanol OR 3- 1.08 furanmethanol 3.13 1-(2-furanyl)-ethanone 0.52 3.55 furan 4.92 3.62 2-pyridinecarboxyaldehyde 0.47 3.81 5-methylfurfural 3.01 3.99 furancarboxylic acid, methyl ester 0.34 4.88 3,4-dimethyl-2,5-furandione 0.53 5.41 2-furancarboxylic acid 1.01 6.37 2-amino-6-hydroxymethylpyridine 1.08 6.67 6-methyl-3-pyridinol 0.49 7.59 2-furancarboxaldehyde 0.47 7.98 picolinamide 0.24 10.34 2H-1-benzopyran-2-one 0.23 16.03 hexadecanoic acid 0.21 17.90 octadecanoic acid 2.97 22.74 erucylamide 10.02

While certain embodiments of the present invention have been described and/or exemplified above, it is contemplated that considerable variation and modification thereof are possible. Accordingly, the present invention is not limited to the particular embodiments described and/or exemplified herein. 

The invention claimed is:
 1. A method of making a glass fiber thermal or acoustical residential building insulation product, wherein the method comprises: spraying a substantially formaldehyde-free, uncured aqueous binder solution onto a mat of glass fibers during production of the thermal or acoustical residential building insulation product such that, once the aqueous binder solution is in contact with the glass fibers, residual heat from the glass fibers and flow of air through the mat evaporates water from the aqueous binder solution to produce a binder coated mat, the aqueous binder solution comprising: Maillard reactants including (i) an amine reactant and (ii) a carbohydrate reactant, wherein the carbohydrate reactant is selected from one or more carbohydrate reactants having one or more reducing sugars, one or more carbohydrate reactants which yield one or more reducing sugars in situ under thermal curing conditions, and combinations thereof and wherein the percent by dry weight of the reducing sugar from the carbohydrate reactant with respect to the total weight of reactants in the aqueous binder solution ranges from about 73% to about 92% and wherein the percent by dry weight of the amine reactant with respect to the total weight of reactants in the aqueous binder solution ranges from about 8% to about 27%; transferring the binder coated mat to and through a curing oven; heating the binder coated mat in the curing oven and curing the binder so as to produce the thermal or acoustical residential building insulation product, wherein i) heated air is passed through the mat to cure the binder in contact with the glass fibers, ii) flights above and below the mat compress the mat to give the insulation product a predetermined thickness and surface finish, and iii) fibrous glass having a cured, rigid binder matrix emerges from the curing oven so as to produce the insulation product in the form of a batt with said glass fibers being present in the insulation product in the range from about 75% to about 99% by weight; and compressing the batt for packaging and shipping to a thickness of less than about 90% of its end of line thickness, such that the method produces an insulation product which, when used to provide thermal insulation, has a density of from about 0.4 lbs/ft³ to about 6 lbs/ft³.
 2. The method of claim 1, wherein the amine reactant is selected from the group consisting of proteins, peptides, amino acids, a compound possessing a primary amino group, a compound possessing a secondary amino group, an ammonium salt of one or more monomeric polycarboxylic acids, and an ammonium salt of one or more polymeric polycarboxylic acids.
 3. The method of claim 1, wherein the carbohydrate reactant includes a monosaccharide reducing sugar selected from the group consisting of dextrose, xylose, fructose, and dihydroxyacetone.
 4. The method of claim 1, wherein the carbohydrate reactant comprises one or more carbohydrate reactants which yield one or more reducing sugars in situ under thermal curing conditions selected from the group consisting of sucrose, lactose, maltose, starch, and cellulose.
 5. The method of claim 1, wherein the uncured aqueous binder solution further comprises an organic acid.
 6. The method of claim 1, wherein the binder further comprises a silicon-containing coupling agent.
 7. The method of claim 1, wherein the binder further comprises a corrosion inhibitor.
 8. The method of claim 1, wherein the uncured aqueous binder solution applied to the mat of fibers has an alkaline pH.
 9. The method of claim 1, wherein binder in contact with the fibers is dehydrated and subsequently cured.
 10. The method of claim 1, wherein curing of the binder generates water-insoluble melanoidins.
 11. A method of making a glass fiber thermal or acoustical residential building insulation product, wherein the method comprises: spraying a substantially formaldehyde-free, uncured aqueous binder solution onto a mat of glass fibers during production of the thermal or acoustical residential building insulation product such that, once the aqueous binder solution is in contact with the glass fibers, residual heat from the glass fibers and flow of air through the mat evaporates water from the aqueous binder solution to produce a binder coated mat, the aqueous binder solution comprising: Maillard reactants including (i) an amine reactant and (ii) a carbohydrate reactant, wherein the carbohydrate reactant is selected from one or more carbohydrate reactants having one or more reducing sugars, one or more carbohydrate reactants which yield one or more reducing sugars in situ under thermal curing conditions, and combinations thereof and wherein the ratio by dry weight of the reducing sugar from the carbohydrate reactant to the amine reactant (expressed as dry weight of reducing sugar/dry weight of amine reactant) is in the range of about 3 to about 12, transferring the binder coated mat to and through a curing oven; heating the binder coated mat in the curing oven and curing the binder so as to produce the thermal or acoustical residential building insulation product, wherein i) heated air is passed through the mat to cure the binder in contact with the glass fibers, ii) flights above and below the mat compress the mat to give the insulation product a predetermined thickness and surface finish, and iii) fibrous glass having a cured, rigid binder matrix emerges from the curing oven so as to produce the insulation product in the form of a batt with said glass fibers being present in the insulation product in the range from about 75% to about 99% by weight; and compressing the batt for packaging and shipping to a thickness of less than about 90% of its end of line thickness, such that the method produces an insulation product which, when used to provide thermal insulation, has a density of from about 0.4 lbs/ft³ to about 6 lbs/ft³.
 12. The method of claim 11, wherein the amine reactant comprises an amine base selected from a primary amine NH₂R¹ and a secondary amine NHR¹R², where R¹ and R² are each independently selected in NHR¹R², R¹ is alkyl which is substituted by at least one group selected from aminoalkyl, amide, nitrile, amino, dialkylamino, acylamino and combinations thereof, and R² is selected from alkyl, cycloalkyl, alkenyl, cycloalkenyl, heterocyclyl, aryl, and heteroaryl, each of which may be optionally substituted.
 13. The method of claim 11, wherein the carbohydrate reactant comprises a carbohydrate selected from the group consisting of a pentose, a pentose used in combination with other reducing sugars, xylose, xylose used in combination with other reducing sugars, a hexose, a hexose used in combination with other reducing sugars, dextrose, dextrose used in combination with other reducing sugars, fructose, fructose used in combination with other reducing sugars, sucrose, and sucrose used in combination with monosaccharides.
 14. The method of claim 11, wherein the amine reactant comprises an ammonium salt of one or more polycarboxylic acids, wherein the ammonium salt includes an ammonium ion selected from the group consisting of ⁺NH₃R¹ and ⁺NH₂R¹R², wherein R¹ and R² are each independently selected in ⁺NH₂R¹R², R¹ is alkyl which is substituted by at least one group selected from aminoalkyl, amide, nitrile, amino, dialkylamino, acylamino and combinations thereof, and wherein R² is selected from alkyl, cycloalkyl, alkenyl, cycloalkenyl, heterocyclyl, aryl, and heteroaryl, each of which may be optionally substituted.
 15. The method of claim 11, wherein curing of the binder comprises i) an initial phase whereby an N-substituted glycosylamine is produced in a Maillard reaction involving condensation of the reducing sugar from the carbohydrate reactant with the amine reactant, ii) rearrangement of the N-substituted glycosylamine, and iii) subsequent esterification-mediated cross-linking.
 16. The method of claim 11, wherein curing forms melanoidins.
 17. The method of claim 11, wherein the uncured aqueous binder solution has a pH of >7.
 18. The method of claim 11, wherein the thermal or acoustical insulation product has a density from about 0.75 lbs/ft³ to about 2.5 lbs/ft³.
 19. The method of claim 11, wherein the curing oven is operated at a temperature over the range from about 350° F. to about 600° F.
 20. The method of claim 11, wherein the cured insulation product has a binder content in the range of about 3% to about 7% as determined by loss on ignition (LOI).
 21. The method of claim 1, wherein the aqueous binder solution comprises ascorbic acid.
 22. The method of claim 11, wherein the aqueous binder solution comprises ascorbic acid. 